Toyota - Tacoma Prerunner Extra - Workshop Manual - 1998 - 1998

Page 868 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released : opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in : closed door). If operation is not as specified, replace the switch Page 4583 1. Assemble these parts to load sensing spring: - Load sensing valve boot - Load sensing spring boot - 4 bushings - 2 rubber plates - 2 collars HINT: Apply lithium soap-base glycol grease to all rubbing areas. - Do not mistake the valve side for the shackle side of the load sensing spring. 2. Install shackle NO.1 and NO.2 a. Install the lock nut and shackle No.1 to the shackle No.2. b. Torque the nut. Torque: 24 Nm (18 ft. lbs.) 3. Install load sensing spring to shackle No.1 a. Install the load sensing spring and 2 plate washer to the shackle No.1. b. Torque the bolt and nut. Torque: 18 Nm (13 ft. lbs.) 4. Install load sensing spring to valve body. Install the load sensing spring to the load sensing valve with the clip. 5. Install valve bracket. a. 2WD: Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts with flexible hose bracket. b. 4WD: Install the set plate to the valve assembly through the valve bracket and temporarily tighten the 2 valve body mounting nuts. c. Torque the bolt and nut with the 2 plate washers. Torque: 18 Nm (13 ft. lbs.) Page 2752 Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Actuator: To Bracket ........................................................................................................................................... ............................................. 9.0 Nm (84 inch lbs.) To ECU ................................................................ ............................................................................................................................ 1.8 Nm (16 inch lbs.) Bracket To Body .......................................................................................................................... ........................................................ 19 Nm (14 ft. lbs.) Page 3633 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 2606 CHART 11 Page 4730 Required SSTs Battery Inspection Procedure All vehicles are to be inspected according to the procedures listed below using the Digital Battery System Analyzer (P/N 00002-V8150-KIT) no more than 48 hours prior to customer vehicle delivery. In hybrid vehicles, the Digital Battery System Analyzer (SST P/N 00002-V81 50-KIT) is to be used ONLY on the AUXILIARY (12 volt) battery. 1. Connect test clamps to the battery. (If the analyzer does NOT power up automatically, press the POWER button.) 2. Select the correct USER ID (if applicable) and press the NEXT soft key. 3. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the NVS-8150 Instruction Manual. Page 652 CHART 23 Page 4188 Finding A Short Circuit 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: 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) Voltage Check Page 1115 Power Steering Fluid: Fluid Type Specifications Power Steering Fluid ........................................................................................................................... ........................................... ATF DEXRON II OR III Page 866 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2186 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Specifications Brake Pedal Assy: Specifications Height: From Asphalt Seat ..................................................................................................................................................... 154.6-164.6 mm (6.087-6.480 inch) Freeplay ............................................................................................................................................... ............................................ 3-6 mm (0.12-0.24 inch) Reserve Distance At: 490 N (110.2 lbs) ................................................................................................................................. .............................. More Than 72 mm (2.83 inch) Page 4728 Above are items that should be checked periodically and their frequency. Summary Chart for Long-Term Storage A combination of proper Vehicle Receipt, Pre-Delivery Service and Vehicle Storage is the only way to maintain factory fresh vehicles. Toyota's goal is to deliver 100% problem-free cars and trucks. With your commitment to quality and customer satisfaction, we can reach that goal. Review this TSB often and be sure new employees are aware of the policies and procedures out-lined herein, as individual training in proper inspection, pre-delivery service, and storage and handling techniques are essential to ensure high delivery quality. Here is a list of additional resources, which will help you with vehicle receipt, inspection and storage procedures. Reference and Training Materials ^ CRIB # 165, Acid Rain Paint Finish Damage - Prevention and Repair ^ UoT e-Learning Course E257 Vehicle Delivery Quality - Paint Finish Repair ^ Dealer Delivery Quality Operations Guide, P/N 00116-DDQ0G-98 ^ BO020-91, Prevention and Repair of Acid Rain Damage ^ BO05-04, New Vehicle Washing Schedule for Paint Protection ^ PG001-06, Battery Maintenance for In Stock Vehicle and Pre-Delivery ^ PA005-04, Iron Particle Rust Contamination Repair ^ PG005-94, Rapgard(TM) Removal Procedures ^ PG007-02, Wheel Film for Brake Rotor Rust Prevention ^ Maintenance for HV & Auxiliary Batteries, Refer to applicable HV models. Page 3058 Ground Points 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. How to Read Power Source Page 2591 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction 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. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description 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 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required 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 Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 4261 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 196 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1403 Page 8 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 518 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2720 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2209 Finding A Short Circuit 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: 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) Voltage Check Page 3634 O/D OFF indicator light remains ON Page 4247 O/D OFF indicator light remains ON Page 2981 (1) Connect the TOYOTA hand-held tester to the DLC3. (2) Turn ignition switch ON and TOYOTA hand-held tester main switch ON. (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. (6) Pinch the fuel return hose. The pressure in high pressure line will rise to approx. 400 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause to hose to crack. (7) Turn the ignition switch to LOCK. (8) Disconnect the TOYOTA hand-held tester from the DLC3. Page 549 Page 1136 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Page 2169 Page 4043 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4009 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 28) Page 4198 Step 2 Step 3 INSPECTION PROCEDURE Specifications Water Pump: Specifications Water Pump Bolts 14 mm head bolt 24.5 Nm (18 ft.lb) 12 mm head bolt 8.9 Nm (78 in.lb) Page 73 Headlamp Dimmer Relay: Testing and Inspection INSPECT HEADLIGHT DIMMER RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 2407 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 174 Page 2816 EGR Temperature Sensor: Testing and Inspection INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 K ohms at 50°C (122°F) 11 - 16 K ohms at 100°C (212°F) 2 - 4 K ohms at 150°C (302°F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 2487 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2085 Page 395 Cruise Control Switch: Electrical Diagrams Page 3097 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3325 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Fuel System - Fuel Injector Cleaning Procedure Fuel Injector: Technical Service Bulletins Fuel System - Fuel Injector Cleaning Procedure PRODUCT GENERAL INFORMATION PG011-05 REVISED October 13, 2005 Title: FUEL INJECTOR CLEANING Models: '90 - '06 Toyota & Scion Models With Port Electronic Fuel Injection TSB REVISION NOTICE: ^ June 9, 2006: In the Required Tools & Material section, part numbers have been updated (TYG S-Line Device and Toyota Adaptor Pak), and the note with ordering information has been updated. Previous versions of this TSB should be discarded. Introduction Due to fuel quality concerns, some Toyota and Scion vehicles with Port Electronic Fuel Injection may experience clogged or blocked fuel injectors. The following procedure has been developed to clean the fuel injectors. Applicable Vehicles: ^ All 1990 - 2006 Toyota and Scion models equipped with Port Electronic Fuel Vehicles Injection (EFI). Required Tools & Material Warranty Information Repair Procedure 1. If the fuel injector nozzles are visibly blocked or if the injectors do NOT pass the fuel injector volume test, complete the fuel injector power flush using the following instructions: A. Before an injector cleaning is performed, it is recommended that the following items be cleaned with Toyota Throttle Plate Cleaner (P/N 00289-1TP00): ^ Idle air control device ^ Throttle plate (both sides if possible) ^ Throttle body B. Bring the engine to operating temperature. C. Disconnect the fuel pump electrical connector. Page 3729 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2688 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3349 O/D OFF indicator light remains ON Page 870 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4865 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 27) Page 2400 Ground Points 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. How to Read Power Source Page 4094 Key to Diagrams Power Window Page 719 Finding A Short Circuit 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: 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) Voltage Check Page 919 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2262 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 569 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3135 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2687 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 730 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 3829 c. Disconnect the throttle cable from the cam. d. Remove the valve body. NOTICE: Be careful not to drop the check ball body and spring. 9. REMOVE SHIFT SOLENOID VALVE a. Remove the solenoid valve mounting bolts. b. Remove the 3 solenoid valves. c. Remove the 3 O-rings from the solenoid valves. 10. INSTALL SHIFT SOLENOID VALVE a. Coat the 3 new O-rings with ATF. b. Install the 3 O-rings to the shift solenoid valves. c. Install the 3 shift solenoid valves with the 3 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) 11. INSTALL VALVE BODY a. Align the groove of the manual valve to the pin of the lever. b. Connect the throttle cable to the cam. Page 2253 Data Link Connector: Testing and Inspection Terminal Identification Reference DLC3 INSPECTION The vehicle's ECM uses the ISO 9141-2 communication protocol. The terminal arrangement of DLC3 complies with SAE J1962 and matches the ISO 9141-2 format. 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. Page 1460 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 3154 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. (f) 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. 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. (g) Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. (h) Install the intake air connector. (i) Install the air cleaner cap and MAF meter assembly. Page 370 Clutch Switch: Description and Operation Denso Made System 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. Page 1787 Page 2171 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Page 1373 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 3007 Idle Speed/Throttle Actuator - Electronic: Component Tests and General Diagnostics Component Inspection INSPECTION 1. 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). Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve. 2. 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. (b) Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO and check that the valve is open. On-Vehicle Inspection ON-VEHICLE INSPECTION INSPECT IAC VALVE OPERATION (a) initial conditions: - Engine at normal operating temperature - idle speed check correctly Page 22 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3043 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Restraints - OCS System Initialization Seat Occupant Classification Module - Air Bag: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 2549 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3338 Overdrive Indicator Lamp: Electrical Diagrams Page 2535 Page 400 Step 2 Step 3 INSPECTION PROCEDURE With Differential Lock Ring Gear: Specifications With Differential Lock Ring Gear Runout: Maximum ............................................................................................................................................. .......................................... 0.10 mm (0.0039 inch) Page 4551 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 455 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 280 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Diagrams Page 1027 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Valve Cover Oil Baffle - Damage Prevention Valve Cover: Technical Service Bulletins Valve Cover Oil Baffle - Damage Prevention ENGINE EG007-02 Title: GENERAL MAINTENANCE TIP Models: All '93 - '03 Models March 22, 2002 Introduction 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. Applicable Vehicles ^ All 1993 - 2003 model year Toyota vehicles. Oil Filling Procedure 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. Warranty Information Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4889 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 682 Oxygen Sensor: Testing and Inspection INSPECTION INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the heated oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohms at 20°C (68°F) Bank 1 Sensor 2: 11 - 16 ohms at 20°C (68°F) if resistance is not as specified, replace the heated oxygen sensor. (c) Reconnect the heated oxygen sensor connector. Page 4265 Page 3308 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 929 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2622 CHART 26 Page 2894 Air Flow Meter/Sensor: Description and Operation 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. Page 1250 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 2117 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3060 Key to Diagrams Power Window Page 4579 2. Remove Load Sensing Proportioning & By-Pass Valve (LSP & BV) assembly. a. Using Special Service Tool (SST) 09023-00100 or equivalent, disconnect the brake lines from the valve body. b. Remove the clip from the flexible hose bracket. c. 2WD: Remove the 3 valve bracket mounting bolts and spacer, and remove the LSP & BV assembly. d. 4WD: Remove the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt, and remove the LSP & BV assembly and flexible hose bracket. INSTALLATION 1. Install LSP & BV assembly to frame. a. 2WD: Install the 3 valve bracket mounting bolts and spacer with the LSP & BV assembly. b. 4WD: Install the 3 valve bracket mounting bolts, spacer and flexible hose bracket mounting bolt with the LSP & BV assembly and flexible hose bracket. Torque: 29 Nm (22 ft. lbs.) 2. Connect brake line. Using SST 09023-00100, connect the brake lines. Torque: 15 Nm (11 ft. lbs.) 3. Connect shackle NO.2 to shackle bracket. a. Set dimension A. Initial set: 2WD: 78 mm (3.07 inch) 4WD: 120 mm (4.72 inch) b. Tighten the lock nut. Torque: 24 Nm (18 ft. lbs.) c. Install the shackle No.2 with the 2 cushions and collar to the shackle bracket. d. Torque the nut with the cushion retainer. Torque: 13 Nm (9 ft. lbs.) 4. Set rear axle load. Rear axle load (includes vehicle weight): 2WD 700 kg (1,543 lbs.) 4WD 850 kg (1,874 lbs.) 5. Set valve body. a. When pulling down the load sensing spring, confirm that the valve piston moves down smoothly. Page 4234 Finding A Short Circuit 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: 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) Voltage Check Specifications Tires: Specifications Cold Tire Inflation Pressure: P225/75R15: Front .................................................................................................................................................... ............................................... 180 kPa (26 psi) Rear .......................................................................... .......................................................................................................................... 200 kPa (29 psi) P265/75R15: Front .................................................................................................................................................... ............................................... 180 kPa (26 psi) Rear .......................................................................... .......................................................................................................................... 180 kPa (26 psi) Page 2307 Step 3 Step 4 Step 5 Step 6 Page 4387 Finding A Short Circuit 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: 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) Voltage Check Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Vehicle - Long Term Storage Guidelines Battery: Technical Service Bulletins Vehicle - Long Term Storage Guidelines T-SB-0079-09 Rev1 March 4, 2009 Long Term Vehicle Storage Guidelines Service Category General Section Maintenance Market USA Applicability December 23, 2009 Rev1: TSB REVISION NOTICE ^ Applicability has been updated to include 2010 Prius PHV model and 2011 vehicles. Any previous printed versions of this service bulletin should be discarded. Introduction Long-term or off-site storage requires special care to keep vehicles factory fresh and ready for delivery. The following guidelines should be performed to minimize vehicle component/part degradation due to extended vehicle storage conditions. Long-term storage can affect a vehicle's systems and components. Any problems that are found should be corrected immediately. Required Tools & Equipment Warranty Information Procedure Page 3114 Key to Diagrams Power Window Page 4398 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2531 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 113 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 806 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1892 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4363 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 791 Air Flow Meter/Sensor: Description and Operation 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. Page 410 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3987 Finding A Short Circuit 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: 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) Voltage Check Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Specifications Clutch: Specifications Overdrive Direct Clutch Clutch Drum Bushing Inside Diameter, Maximum .......................................................................................................................... 27.11 mm (1.0673 inch) Overdrive Direct Clutch Piston Stroke Supra ................................................................................................................................................... .................. 1.45 - 1.70 mm (0.0571 - 0.0669 inch) Others ................................................................. ................................................................................................... 1.85 - 2.15 mm (0.0728 - 0.0846 inch) Overdrive Planetary Gear Bushing, Maximum ................................................................................................................................ 11.27 mm (0.4437 inch) Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. .......................................................................................................................... 1.00 mm (0.0394 inch) Flange Thickness No. 16 .................................................................................................................................................. .............................................. 3.6 mm (0.142 inch) No. 17 .................................................................. .............................................................................................................................. 3.5 mm (0.138 inch) No. 18 ......................................................................................................................................... ....................................................... 3.4 mm (0.134 inch) No. 19 ......................................................... ....................................................................................................................................... 3.3 mm (0.130 inch) No. 20 .............................................................................................................................. .................................................................. 3.2 mm (0.126 inch) No. 21 .............................................. .................................................................................................................................................. 3.1 mm (0.122 inch) Overdrive Brake Piston Stroke Previa .................................................................................................................................................. .................. 1.32 - 1.62 mm (0.0520 - 0.0638 inch) Others ................................................................. ................................................................................................... 1.40 - 1.70 mm (0.0551 - 0.0669 inch) Flange Thickness No. 77 .................................................................................................................................................. .............................................. 3.3 mm (0.130 inch) No. 78 .................................................................. .............................................................................................................................. 3.5 mm (0.138 inch) No. 79 ......................................................................................................................................... ....................................................... 3.6 mm (0.142 inch) No. 80 ......................................................... ....................................................................................................................................... 3.7 mm (0.146 inch) No. 81 .............................................................................................................................. .................................................................. 3.8 mm (0.150 inch) No. 82 .............................................. .................................................................................................................................................. 3.9 mm (0.154 inch) None ......................................................................................................................... ......................................................................... 4.0 mm (0.157 inch) Direct Clutch Piston Stroke ............................................................................................................................................................. 1.37 - 1.60 mm (0.0359 - 0.0630 inch) Drum Bushing Inside Diameter ....................................................................................................................................................... 53.99 mm (2.1256 inch) Flange Thickness No. 33 .................................................................................................................................................. .............................................. 3.0 mm (0.118 inch) No. 32 .................................................................. .............................................................................................................................. 3.1 mm (0.122 inch) No. 31 ......................................................................................................................................... ....................................................... 3.2 mm (0.126 inch) No. 32 ......................................................... ....................................................................................................................................... 3.3 mm (0.130 inch) No. 29 .............................................................................................................................. .................................................................. 3.4 mm (0.134 inch) No. 28 .............................................. .................................................................................................................................................. 3.5 mm (0.138 inch) No. 27 ....................................................................................................................... ......................................................................... 3.6 mm (0.142 inch) No. 34 ....................................... ......................................................................................................................................................... 3.7 mm (0.146 inch) Forward Clutch Pack Clearance .......................................................................................................... ........................................................ 0.5 - 0.9 mm (0.020 - 0.035 inch) Drum Bushing Inside Diameter ....................................................................................................................................................... 24.08 mm (0.9480 inch) Flange Thickness No. 61 .................................................................................................................................................. .............................................. 3.0 mm (0.118 inch) No. 60 .................................................................. .............................................................................................................................. 3.2 mm (0.126 inch) No. 45 ......................................................................................................................................... ....................................................... 3.4 mm (0.134 inch) No. 62 ......................................................... ....................................................................................................................................... 3.6 mm (0.142 inch) No. 44 .............................................................................................................................. .................................................................. 3.8 mm (0.150 inch) No. 42 .............................................. .................................................................................................................................................. 4.0 mm (0.157 inch) No. 63 ....................................................................................................................... ......................................................................... 4.2 mm (0.165 inch) No. 64 ....................................... ......................................................................................................................................................... 4.4 mm (0.173 inch) Second Brake Pack Clearance .......................................................................................................................................................... 0.62 - 1.98 mm (0.0244 - 1.1780 inch) First and Reverse Brake Pack Clearance .......................................................................................................................................................... 0.60 - 1.12 mm (0.0236 - 0.0441 inch) Flange Thickness No. 50 .................................................................................................................................................. .............................................. 5.0 mm (0.197 inch) No. 51 .................................................................. .............................................................................................................................. 4.8 mm (0.189 inch) Page 2846 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1068 Hose/Line HVAC: Service and Repair LOCATION 1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM 2. REPLACE FAULTY TUBE OR HOSE NOTE: Cap the open fittings immediately to keep moisture or dirt out of the system. 3. TIGHTEN JOINT OF BOLT OR NUT AT SPECIFIED TORQUE NOTE: Connections should not be torqued tighter than the specified torque. 4. EVACUATE AIR IN REFRIGERATION SYSTEM AND CHARGE WITH REFRIGERANT Specified amount: 600 ± 50 g (21.16 ± 1.76 oz.) 5. INSPECT FOR LEAKAGE OF REFRIGERANT Using a gas leak detector, check for leakage of refrigerant. Page 4409 Finding A Short Circuit 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: 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) Voltage Check Locations Page 3790 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4553 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 548 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 723 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Testing and Inspection Idle Speed/Throttle Actuator - Mechanical: Testing and Inspection THROTTLE OPENER INSPECTION (a) Allow the engine to warm up to normal operating temperature. (b) Check the idle speed. Idle speed: 650 - 750 rpm (c) Disconnect the vacuum hose from the throttle opener and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 1,200 - 1,500 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. (h) Disconnect TOYOTA hand-held tester or OBD II scan tool. Page 605 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2250 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4293 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2201 Key to Diagrams Power Window Page 3645 Ground Points 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. How to Read Power Source Page 2573 Finding A Short Circuit 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: 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) Voltage Check Page 721 Page 4465 3. Check pedal freeplay. a. Stop the engine and depress the brake pedal several times until there is no more vacuum left in the booster. b. Push in the pedal by hand until the beginning of the second resistance is felt. Measure the distance. Pedal freeplay: 3 - 6 mm (0.12 - 0.24 inch) HINT: The freeplay to the 1st resistance is due to the play between the clevis and pin. This is magnified up to 1 - 3 mm (0.04 - 0.12 inch) at the pedal. If correct, check the stop light switch clearance. If the clearance is OK, then troubleshoot the brake system. 4. 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, 'a', at 490 N (110.2 lbs.): More than 72 mm (2.83 inch) If incorrect, troubleshoot the brake system. Page 3125 Page 1718 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2485 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1984 Page 2534 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2045 b. Check and correct the cause if necessary. Page 784 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2243 Key to Diagrams Power Window Page 1412 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe from the fan shroud. 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE OIL DIPSTICK GUIDE a. Remove the bolt, dipstick guide and engine wire bracket. b. Remove the O-ring from the dipstick guide. HINT: At the time of installation, please refer to the following items. Use a new O-ring. Diagrams Page 4013 Locations-R/B No.2-Engine Compartment Left (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND: Approx 13 Ohms P 1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 4-GROUND: Approx. 12 Volts with ignition SW ON position S 5 STOP LIGHT SW 1-2: Closed with Brake Pedal Depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open Page 2838 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points A/C Drive Belt: Testing and Inspection A/C 1. INSPECT DRIVE BELT'S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt : 160 ± 25 lb Used belt : 100 ± 20 lb 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 the drive belt, check that it fits properly in the ribbed grooves. Page 3708 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2668 Page 1236 Piston Ring: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 1993 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2585 A/F and 02 Sensor Identification Page 4366 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3329 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2145 Finding A Short Circuit 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: 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) Voltage Check Page 2479 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Testing and Inspection Power Steering Pressure Switch: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF. 2. CHECK IDLE-UP. a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 2384 CHART 23 Page 4893 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2223 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4315 Page 1510 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2524 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Specifications Firing Order: Specifications Firing order: 1-3-4-2 Page 3772 Shift Solenoid: Description and Operation DESCRIPTION Shift Solenoid 1-2 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.). 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. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunctioning, hydraulic control cannot be performed electronically and must be done manually. Shift Solenoid Valve SL 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. Page 2675 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3897 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 120 Finding A Short Circuit 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: 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) Voltage Check Page 660 Page 2928 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3340 Overdrive Indicator Lamp: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 1850 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4748 4. INSPECT 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. 5. INSPECT 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. 6. INSPECT EXPOSED BRUSH LENGTH Using a scale, measure the exposed brush length. Standard exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) Minimum exposed length: 1.5 mm (0.059 in.) If the exposed length is less than the minimum, replace the brushes. 7. IF NECESSARY, REPLACE BRUSHES Page 2658 Key to Diagrams Power Window Page 873 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 261 Page 4385 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3194 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2322 Key to Diagrams Power Window Page 1739 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 90 Tail Lamp Relay: Testing and Inspection INSPECT TAILLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1735 Key to Diagrams Power Window Page 1214 Connecting Rod: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 1580 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2646 Oxygen Sensor: Description and Operation 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 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 in 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 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 temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 2327 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 803 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2140 Brake Signal: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1977 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3192 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2874 b. Check and correct the cause if necessary. Page 3218 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4576 3,920 kPa (570 psi) 6,860 kPa (997.5 psi) Rear brake pressure 1,960 kPa (285 psi) 2,450 ± 196 kPa (356 ± 28.5 psi) 3,190 ± 343 kPa (463 ± 50 psi) 4WD: Front brake pressure 1,470 kPa (213.5 psi) 3,920 kPa (570 psi) 6,860 kPa (997.5 psi) Rear brake pressure 1,470 kPa (213.5 psi) 1,960 ± 196 kPa (285 ± 28.5 psi) 2,550 ± 343 kPa (370.5 ± 50 psi) If the measured value is not within standard, replace the valve body. Page 3405 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4129 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4453 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 19 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2886 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1971 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3639 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2763 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3910 a. Coat a new oil seal lip with MP grease. b. 2RZ-FE: Using SST and a hammer, install the oil seal. SST 09554-30011 Oil seal drive in depth: 1.5 mm (0.059 inch) c. 3RZ-FE, 5VZ-FE w/o Diff. lock: Using SST and a plastic hammer, install the oil seal until its surface is flush with the differential carrier end. SST 09316-12010, 09649-17010 Oil seal drive in depth: 0.5 mm (0.020 inch) HINT: Connect SST with vinyl tape. d. 3RZ-FE, 5VZ-FE w/ Diff. lock: Using SST and a hammer, install the oil seal. SST 09214-76011 Oil seal drive in depth: 1.0 mm (0.039 inch) 13. INSTALL COMPANION FLANGE a. Place the companion flange on the drive pinion. b. Coat the threads of a new nut with hypoid gear oil. c. Using SST to hold the flange, torque the nut. SST 09330-00021 Page 2293 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1246 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 2033 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 1633 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4774 9. 2.0 kW type: INSPECT FIELD COIL RESISTANCE Using an ohmmeter, measure the resistance between the lead wire and field frame. Resistance: 1.5 - 1.9 Ohms At 20 °C (68 °F) If the resistance is not as specified, replace the field frame. 10. INSPECT BRUSH LENGTH Using vernier calipers, measure the brush length. Standard length: 1.4 kW type: 15.5 mm (0.610 in.) 2.0 kW type: 15.0 mm (0.591 in.) Minimum length: 1.4 kW type: 10.0 mm (0.394 in.) 2.0 kW type: 9.0 mm (0.355 in.) If the length is less than the minimum, replace the brush holder and field frame. 11. INSPECT BRUSH SPRING LOAD Take the pull scale reading the instant the brush spring separates from the brush. Spring installed load: 1.4 kW type: 17.6 - 23.5 N (1.79 - 2.41 kgf, 3.9 - 5.3 lbf) 2.0 kW type: 21.5 - 27.5 N (2.19 2.81 kgf, 4.9 - 6.2 lbf) Minimum spring installed load: 1.4 kW type: 11.8 N (1.2 kgf, 2.6 lbf) 2.0 kW type: 12.7 N (1.3 kgf, 2.7 lbf) Description and Operation Malfunction Indicator Lamp: Description and Operation 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 Diagnostic Trouble Code (DTC) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction has been repaired, the MIL goes off automatically but the DTCs remain recorded in the ECM memory. Page 3764 Shift Solenoid: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4329 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4648 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3092 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 515 Ground Points 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. How to Read Power Source Page 2995 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1778 Engine Bank Identification Page 4862 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 34) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Page 786 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 628 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 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. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," 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. Example: Page 48 Blower Motor Relay: Testing and Inspection INSPECT HEATER MAIN RELAY (Marking: HTR) CONTINUITY If continuity is not as specified, replace the relay. Page 3597 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Electronically Controlled Transmission And A/T Indicator-Connectors Page 4666 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1591 Finding A Short Circuit 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: 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) Voltage Check Page 3062 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 921 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2166 Finding A Short Circuit 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: 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) Voltage Check Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 757 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 1421 Coolant: Service Precautions 1. Toyota Long Life Antifreeze Coolant is recommended by the manufacturer for maximum protection. 2. Mixing green and red colored coolants is not recommended. Page 983 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: RZN161L model RZN 171L model RZN191L model RZN196L model VZN170L model Page 4440 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2157 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 821 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 702 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2404 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3701 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 790 Page 61 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1988 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 2765 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3585 Position Of Parts In Instrument Panel (1 Of 2) (Fig 30) Page 3068 Finding A Short Circuit 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: 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) Voltage Check Page 1795 CHART 11 Page 1124 Refrigerant: Fluid Type Specifications Type R134a Page 1679 Finding A Short Circuit 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: 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) Voltage Check Page 385 Key to Diagrams Power Window Page 3467 Key to Diagrams Power Window Page 4808 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3617 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 127 Engine Control Module: Testing and Inspection Related Diagnostic Procedures 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 (Making: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 2544 Ground Points 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. How to Read Power Source Page 3173 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2633 Ground Points 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. How to Read Power Source O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 1690 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Specifications Firing Order: Specifications Firing order: 1-3-4-2 System Diagnosis Air/Fuel Mixture: Testing and Inspection 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 systems, etc. should be properly connected. f. Sequential Multiport Fuel Injection (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 APPROXIMATELY 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. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. a. Check heated oxygen sensor operation. Page 366 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 559 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2887 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Capacity Specifications Refrigerant Oil: Capacity Specifications When Replacing, Add: Receiver 20 cc Condenser 40 cc Evaporator 40 to 50 cc Page 3039 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2532 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 3476 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3562 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 637 CHART 5 CHART 6 Page 3174 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4497 Page 1530 Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 3050 Air Flow Meter/Sensor: Description and Operation 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. Page 3079 Throttle Body: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT 2. M/T: DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY A/T: DISCONNECT ACCELERATOR AND THROTTLE CABLES FROM THROTTLE BODY 3. REMOVE AIR CLEANER HOSE WITH RESONATOR (a) Disconnect the 2 wire clamps from the air cleaner hose. (b) Loosen the air cleaner hose clamps, remove the air cleaner together with the resonator. 4. REMOVE INTAKE AIR CONNECTOR (a) Disconnect these air hoses and wire clamp: (1) Air hose for IAC (2) Vacuum sensing hose (3) Wire clamp for engine wire (b) Remove the 2 bolts, hose clamp and intake air connector. 5. REMOVE PCV HOSE 6. REMOVE THROTTLE BODY (a) Disconnect these hoses: (1) 3 vacuum hoses (2) EVAP hose (3) w/PS: Air hose for PS idle-up (b) Disconnect the throttle position sensor connector. (c) Disconnect the IAC valve connector. Page 1737 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3979 Key to Diagrams Power Window Page 1367 Idle Speed: Testing and Inspection 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. Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the Idle Air Control (IAC) valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 3175 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2850 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Diagrams Fuel Supply Line: Diagrams COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 635 CHART 1 Page 1776 Applicable Vehicles Page 851 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4556 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Specifications Carrier Side Gears: Specifications Side Gear Backlash ....................................................................................................................................................... 0.05-0.20 mm (0.0020-0.0079 inch) Page 1413 6. w/PS: REMOVE DRIVE BELT FOR PS PUMP Loosen the lock bolt and adjusting bolt, and remove the drive belt. 7. REMOVE FAN SHROUDS a. Remove the 2 clips and No.2 fan shroud. b. Remove the 4 bolts and No.1 fan shroud. 8. w/ A/C: REMOVE DRIVE BELT FOR A/C COMPRESSOR Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. 9. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY a. Stretch the belt and loosen the water pump pulley nuts. b. Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belt. c. Remove the 4 water pump pulley nuts. Torque: 21 Nm (210 kgf.cm, 16 ft. lbs.) d. Pull out the fan together with the fluid coupling and water pump pulley. 10. REMOVE WATER PUMP Remove the 10 bolts, water pump and gasket. Torque: 14 mm head bolt: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 12 mm head bolt: 8.9 Nm (90 kgf.cm, 78 inch lbs.) HINT: At the time of installation, please refer to the following items. Use a new gasket. Page 3520 Page 3730 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3690 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1678 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3144 Finding A Short Circuit 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: 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) Voltage Check Page 1914 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2279 Chart 2 Of 2 Page 162 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 503 Finding A Short Circuit 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: 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) Voltage Check Page 1491 2. REMOVE RADIATOR SUPPORTS Remove the 4 screws and 2 radiator supports. HINT: At the time of assembly, please refer to the following items. Insert the tabs the radiator upper tank through the radiator support holes. Torque: 5.5 Nm (55 kgf.cm, 49 inch lbs.) REASSEMBLY Reassembly is in the reverse order of disassembly. INSTALLATION Installation is in the reverse order of removal. Page 4099 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Chart 1 Of 2 Page 1028 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 3268 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4321 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Diagram Information and Instructions Igniter: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2890 Finding A Short Circuit 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: 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) Voltage Check Page 1051 Assenmacher Specialty Tools 1-800-525-2943 Page 4406 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 284 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Specifications Drive Belt: Specifications Drive Belt Tension: New Belt .............................................................................................................................................. .......................................................... 135-180 lbs. Used Belt ............................................................................................................................................. ............................................................. 85-120 lbs. Page 920 Key to Diagrams Power Window Page 4871 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 653 Page 3096 Finding A Short Circuit 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: 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) Voltage Check Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 651 Page 2207 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2545 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 241 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1144 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 126 Chart 2 Of 2 Page 4371 Page 2406 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3040 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1755 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2716 Ground Points 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. How to Read Power Source Page 1455 Finding A Short Circuit 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: 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) Voltage Check Page 592 Intake Air Temperature Sensor: Description and Operation 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. Figure 1 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. 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 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. Page 4228 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 505 Page 2741 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 936 Step 2 Step 3 INSPECTION PROCEDURE Page 1096 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ..................................................... API GL-4 or GL-5 Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 Page 83 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2006 Page 807 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4367 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3009 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. INSTALLATION 1. INSTALL IAC VALVE (a) Place a new gasket on the throttle body. (b) install the IAC valve with the 4 screws. 2. INSTALL THROTTLE BODY Page 2880 Ground Points 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. How to Read Power Source Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Diagram Information and Instructions ABS Light: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 255 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 426 Air Conditioning Switch: Service and Repair REMOVAL REMOVE A/C SWITCH a. Cover the switch with a cloth. b. Using pliers, pull out the switch. INSTALLATION Installation is in the reverse order of removal. Page 338 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2107 Page 3685 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4842 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4565 Page 3707 Finding A Short Circuit 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: 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) Voltage Check Page 2785 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Page 4285 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 852 Page 2137 Key to Diagrams Power Window Page 1799 CHART 16 CHART 17 Page 2568 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 679 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1936 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 844 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2129 Intake Air Temperature Sensor: Description and Operation 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. Figure 1 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. 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 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. Page 2144 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1685 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4369 Finding A Short Circuit 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: 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) Voltage Check Page 502 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1229 Piston: Service and Repair For information regarding the Service and Repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Specifications Exhaust Manifold: Specifications Exhaust Manifold Fasteners 49 Nm (36 ft.lb) Heat Insulator 5.5 Nm (48 in.lb) Page 2639 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL 1. Remove brake line cover. Page 2003 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1744 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3825 Page 1982 Finding A Short Circuit 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: 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) Voltage Check Page 1497 Required SSTs Radiator Cap Identification Procedure 1. Use the illustration below to identify the vehicle's radiator cap type and kPa rating. 2. Proceed to the required inspection procedure for the radiator cap and kPa rating. Radiator Cap Inspection Procedure Type: N-cap, 88 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B," and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) Page 2302 Diagram Information and Instructions Igniter: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 249 Ground Points 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. How to Read Power Source Page 2387 CHART 25 Page 1899 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 1241 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 3242 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Testing and Inspection Air Conditioning Switch: Testing and Inspection 1. INSPECT A/C INDICATOR OPERATION a. Connect the positive (+) lead from the battery to terminal 6 and the negative (-) lead to terminal 4. b. Push the A/C button in and then check that the indicator lights up. If operation is not as specified, replace the switch. 2. INSPECT DIMMING OPERATION a. Connect positive (+) lead from the battery to terminal 6 and negative (-) lead to terminal 4 and 1. b. Connect the positive (+) lead from the battery to terminal 3 and then check that the indicator dims. If operation is not as specified, replace the switch. 3. INSPECT A/C SWITCH CONTINUITY If operation is not as specified, replace the switch or test the bulb. Page 232 Key to Diagrams Power Window Page 606 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4223 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1348 b. Apply seal packing to the oil pan 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 inch) opening or 3 - 4 mm (0.012 0.016 inch) opening. HINT: Avoid applying an excessive amount to the surface. ^ Parts must be assembled within 5 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 16 bolts and 2 nuts. Torque: 12.5 Nm (130 kgf.cm, 9 ft. lbs.) 13. INSTALL FLYWHEEL HOUSING UNDER COVER AND DUST SEAL 14. 2WD: INSTALL STIFFENER PLATES Torque: 37 Nm (380 kgf.cm, 27 ft. lbs.) 15. INSTALL CRANKSHAFT POSITION SENSOR Install a new O-ring. Torque: 8.5 Nm (85 kgf.cm,74 inch lbs.) 16. INSTALL GENERATOR, ADJUSTING BAR AND BRACKET a. Install the bracket with the 3 bolts. Torque: Bolt A: 74.5 Nm (760 kgf.cm, 55 ft. lbs.) Bolt B: 18 Nm (185 kgf.cm, 13 ft. lbs.) b. Install the adjusting bar with the bolt. Torque: 63.5 Nm (650 kgf.cm, 47 ft. lbs.) c. Install the generator with the pivot bolt and lock bolt. 17. w/ A/C: INSTALL A/C COMPRESSOR AND BRACKET a. Install the A/C compressor bracket with the 4 bolts. Torque: 44 Nm (440 kgf.cm, 32 ft. lbs.) b. Install the A/C compressor with the 4 bolts. Torque: 25 Nm (250 kgf.cm, 18 ft. lbs.) 18. INSTALL CYLINDER HEAD ASSEMBLY 19. INSTALL WATER PUMP PULLEY, FAN WITH FLUID COUPLING AND DRIVE BELT FOR GENERATOR 20. 4WD: INSTALL FRONT DIFFERENTIAL AND DRIVE SHAFTS ASSEMBLY 21. FILL WITH ENGINE OIL 22. START ENGINE AND CHECK FOR LEAKS 23. INSTALL ENGINE UNDER COVER 24. VEHICLE ROAD TEST Check for abnormal noise, shock slippage, correct shift points and smooth operation. 25. RECHECK ENGINE COOLANT AND ENGINE OIL LEVEL Page 1675 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 528 Page 2249 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2932 Page 3569 Step 2 Step 3 INSPECTION PROCEDURE Page 2986 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Page 4734 Battery Charging Procedure If the battery requires charging, follow the procedures below using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8). 1. Connect the charger cables to the positive (+) and negative (-) battery terminals. 2. Plug the charger into the 110V outlet and turn the switch to the ON position. 3. Select appropriate USER ID (if applicable) and press the NEXT soft key. 4. Enter USER PIN (if applicable) and press the NEXT soft key. NOTE: For details on defining USER ID or PIN, refer to the GR8 Instruction Manual. 5. Press the NEXT soft key when the HELLO screen appears to proceed to the Main Menu. Page 1917 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 318 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 826 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 100 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 342 Brake Switch (Cruise Control): Description and Operation Denso Made System CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. 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 is cut mechanically by the stop light switch, turning the cruise control off. Page 1465 Installation is in the reverse order of removal. Page 4262 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2248 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1800 CHART 18 CHART 19 Page 843 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 289 Wheel Speed Sensor: Description and Operation CIRCUIT DESCRIPTION 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. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 2940 (i) Connect the vacuum sensing hose to the fuel pressure regulator. 3. CONNECT ENGINE WIRE 4. INSTALL THROTTLE BODY Page 1865 Key to Diagrams Power Window Page 4105 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 4459 Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 2770 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 1957 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2027 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Testing and Inspection Headlamp Switch: Testing and Inspection INSPECT LIGHT CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2705 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3793 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4031 Step 2 Step 3 INSPECTION PROCEDURE Specifications Brake Master Cylinder: Specifications Master Cylinder To: Piston Stopper Bolt .............................................................................................................................. ............................................ 8.0 Nm (69 inch lbs.) Reservoir .............................................................. ............................................................................................................................ 1.5 Nm (13 inch lbs.) Brake Booster .............................................................................................................................. .................................................... 13 Nm (108 inch lbs.) Page 317 Page 1851 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 2396 Page 3619 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3798 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4830 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3239 Page 3596 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3413 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4690 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 2509 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 71 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2319 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Removal and Installation Generator: Service and Repair Removal and Installation COMPONENTS REMOVAL Page 4271 Page 788 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2764 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2618 Page 2562 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4165 Step 3 Page 1438 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. Page 279 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3851 Carrier Side Gears: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Differential; Service and Repair. Page 2851 Specifications Fuel Tank: Specifications Fuel Tank Capacity: 15.1 gal. (57 liters) Specifications Crankshaft Main Bearing: Specifications Main Bearing Oil Clearance Standard Clearance No.3 - Std. 0.030-0.055 mm Others - Std. 0.024-0.049 mm No.3 - U/S 0.25 0.030-0.070 mm Others - U/S 0.25 0.025-0.065 mm Maximum Clearance 0.10 mm Bearing Center Wall Thickness Std. Mark "1" 1.987-1.990 mm Std. Mark "2" 1.991-1.993 mm Std. Mark "3" 1.994-1.996 mm U/S 0.25 2.106-2.112 mm Main Bearing Cap Bolts Step 1 39 Nm (29 ft.lb) Step 2 Turn 90 degrees Page 3453 Page 875 Finding A Short Circuit 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: 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) Voltage Check Page 3047 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4026 Electronically Controlled Transmission (Part 3 Of 3) Page 3118 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 398 Step 2 Step 3 INSPECTION PROCEDURE Page 2334 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 1659 Page 2667 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3826 Valve Body: Service and Repair ON-VEHICLE REPAIR CAUTION: When working with FIPG material, you must observe the followings. - Using a razor blade and a gasket scraper, remove all old FIPG material from the gasket surfaces. - Thoroughly clean all components to remove all loose material. - Clean both sealing surfaces with a non-residue solvent. - Apply FIPG in an approx. 1 mm (0.04 inch) wide bead along the sealing surface. - Parts must be assembled within 10 minutes of application. - Otherwise, the FIPG material must be removed and reapplied. 1 REMOVE DRAIN PLUG AND DRAIN ATF 2. REMOVE OIL PAN NOTICE: Some fluid will remain in the oil pan. a. Remove the 19 bolts. b. Install the blade of SST between the transmission case and oil pan, cut off applied sealer, and remove the oil pan. SST 09032 - 00100 NOTICE: When removing the oil pan, be careful not to damage the oil pan flange. 3. EXAMINE PARTICLES IN PAN Remove the magnets and use them to collect steel particles. Carefully look at the foreign matter and particles in the pan and on the magnets to anticipate the type of wear you will find in the transmission. Steel (magnetic) ... bearing, gear and clutch plate wear Brass (non-magnetic) ... bushing wear Page 4210 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3646 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1830 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Specifications Wheel Speed Sensor: Specifications Speed Sensor Installation Bolt 71 in.lb Front Speed Sensor Harness To: Upper Arm 71 in.lb Side Rail 108 in.lb Rear Speed Sensor Harness To: Axle Housing 108 in.lb Fuel Tank 108 in.lb Side Rail 108 in.lb Page 2761 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 418 Vehicle Speed Sensor/Transducer - Cruise Control: Electrical Diagrams Page 4672 Specifications Wheel Fastener: Specifications Hub/Lug Nut ........................................................................................................................................ ................................................... 110 Nm (83 ft. lbs.) Page 4564 Page 3196 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3434 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1752 Ground Points 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. How to Read Power Source Page 4747 Generator: Testing and Inspection 1. INSPECT ROTOR FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the slip rings. Standard resistance (Cold): 2.1 - 2.5 Ohms If there is no continuity, replace the rotor. 2. INSPECT 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. 3. INSPECT SLIP RINGS a. Check that the slip rings are not rough or scored. If rough or scored, replace the rotor. b. Using a vernier caliper, 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 the minimum, replace the rotor. Page 1335 Page 4103 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 819 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 220 If continuity is not as specified, replace the switch. RH: If continuity is not as specified, replace the switch. INSPECT DRIVER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR UNLOCK DETECTION SWITCH CONTINUITY If continuity is not as specified, replace the switch. Diagrams Fuel Return Line: Diagrams COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. Page 242 Page 542 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1831 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications ABS Actuator: To Bracket ........................................................................................................................................... ............................................. 9.0 Nm (84 inch lbs.) To ECU ................................................................ ............................................................................................................................ 1.8 Nm (16 inch lbs.) Bracket To Body .......................................................................................................................... ........................................................ 19 Nm (14 ft. lbs.) Page 2472 Air Flow Meter/Sensor: Description and Operation 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. Page 3622 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1160 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4629 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3767 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1402 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 2757 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1646 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2680 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2373 CHART 11 Page 4433 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3361 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Relay Blocks Relay Blocks Page 3773 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.). 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. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3898 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1048 Drive Belt: Testing and Inspection Power Steering INSPECTION 1. 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 Drive belt tension: New belt: 135-180 lbs. - Used belt: 85 -120 lbs. 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. - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Page 1827 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2804 (b) Apply battery positive voltage across the terminals. (c) Check that air flows from ports E to F and does not flow from ports E to P. If operation is not as specified, replace the VSV. 5. REINSTALL VSV Page 201 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1702 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 286 Finding A Short Circuit 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: 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) Voltage Check Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Refill With Filter ................................................................................................................................... ....................................................................... 5.8 Qt Without Filter ....................................................................................................................................... ........................................................................ 5.0 Qt NOTE: Listed capacities are approximate. Check fluid level after filling. Page 359 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4847 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 119 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 639 CHART 8 CHART 9 Page 1911 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4780 COMPONENTS REMOVAL REMOVE STARTER Page 178 2. INSTALL REMOVED PARTS Page 4401 Key to Diagrams Power Window Page 1930 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 841 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. A/T - Torque Converter Bolt Installation Precautions Flex Plate: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 4630 Page 2692 Page 4333 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 677 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4335 Acceleration/Deceleration Sensor: Description and Operation CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions¢4mtions abnormally. The ECU cuts off current to the ABS control (solenoid) relay and prohibit ABS control¢0m. Page 2426 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1581 Ground Points 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. How to Read Power Source Page 982 Alignment: Service and Repair NOTICE: - RZN161L: Tacoma Regular Cab 4WD 2.7L DOHC (3RZ-FE) - RZN171L: Tacoma Extra Cab 4WD 2.7L DOHC (3RZ-FE) - RZN191L: Tacoma Prerunner Reg Cab 2WD 2.7L (3RZ-FE) - RZN196L: Tacoma Prerunner Extra Cab 2WD 2.7L DOHC (3RZ-FE) - VZN170L: Tacoma Extra Cab 4WD 3.4L DOHC (5VZ-FE) - VZN195L: Tacoma Prerunner Extra Cab 2WD 3.4L DOHC (5VZ-FE) INSPECTION HINT: Pre runner is the model described below. 1. MEASURE VEHICLE HEIGHT Vehicle height: Measuring points: A: Ground clearance of spindle center. B: Ground clearance of front adjusting cam bolt center. C: Ground clearance of leaf spring front hanger pin bolt center. D: Ground clearance of rear axle shaft center. 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. Page 2097 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2642 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2929 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1733 Ground Points 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. How to Read Power Source Page 135 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 591 Page 4697 Finding A Short Circuit 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: 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) Voltage Check Page 824 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4714 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2401 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3248 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3587 Locations-R/B No.2-Engine Compartment Left (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND: Approx 13 Ohms P 1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 4-GROUND: Approx. 12 Volts with ignition SW ON position S 5 STOP LIGHT SW 1-2: Closed with Brake Pedal Depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open Injection Inspection Fuel Injector: Testing and Inspection Injection Inspection INSPECTION 1. INSPECT INJECTOR INJECTION CAUTION: Keep injector clean of sparks during the test. (a) Remove the fuel in let pipe from the fuel tiller outlet. (b) Connect SST (union and hose) to the fuel filter outlet with the 2 gaskets and union bolt. SST 09268-41046 (90405-09015) Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (c) Remove the fuel pressure regulator from the delivery pipe. (d) Install the O-ring to the fuel inlet of pressure regulator. (e) Connect SST (hose) to the fuel inlet of the pressure regulator with SST (union) and the 2 bolts. SST 09268-41046 (09268-41091) (f) Connect the fuel return hose to the fuel outlet of the pressure regulator. (g) Install the O-ring to the injector. Page 1384 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS (a) Remove the air cleaner cap and MAF meter assembly. (b) Remove the intake air connector. (c) Disconnect the high-tension cords from the spark plugs. NOTICE: Pulling on or bending the cords may damage the conductor inside. (d) 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. (e) Using an ohmmeter, measure the resistance. Maximum resistance: 25 k ohms per cord Page 2161 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4752 e. Place the generator washer on the rotor. Page 657 CHART 26 Page 1868 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 780 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2024 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2706 Finding A Short Circuit 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: 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) Voltage Check Page 3903 Ring Gear: Specifications Less Differential Lock Ring Gear Runout: Maximum ............................................................................................................................................. .......................................... 0.05 mm (0.0020 inch) Page 117 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 566 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4377 Ground Points 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. How to Read Power Source Page 453 Key Reminder Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Locations Page 3177 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4410 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2163 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Locations O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 297 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2679 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Removal and Installation Brake Master Cylinder: Service and Repair Removal and Installation REMOVAL 1. 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. Using Special Service Tool (SST) 09023-00100 or equivalent, disconnect the 5 brake lines. Torque: 15 Nm (11 ft. lbs.) 4. Remove master cylinder. Page 587 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 949 Key to Diagrams Power Window Page 3565 Overdrive Indicator Lamp: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 1414 INSPECTION 1. INSPECT WATER PUMP a. Visually check the air hole and 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 FLUID COUPLING a. Remove the 4 nuts and fan from the fluid coupling. b. Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c. Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf.cm, 49 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 3318 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.). 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. Page 2743 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 376 Step 2 Step 3 Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1278 Drive Belt: Testing and Inspection Power Steering INSPECTION 1. 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 Drive belt tension: New belt: 135-180 lbs. - Used belt: 85 -120 lbs. 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. - After installing a new belt, run the engine for about 5 minutes and recheck the belt tension. Page 4474 Brake Caliper: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Remove cylinder boot set rings and boots. Using a screwdriver, remove the 4 cylinder boot set rings and boots. 2. Remove pistons from cylinder. a. Prepare the wooden plate to hold the pistons. b. Place the plate between the pistons and insert a pad at one side. Page 2296 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2968 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (c) 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. (d) Install the injector to the delivery pipe and cylinder head as shown in the illustration. (e) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. (1) Connect the TOYOTA hand-held tester to the DLC3. (2) Turn ignition switch ON and TOYOTA hand-held tester main switch ON. (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. (6) Pinch the fuel return hose. The pressure in high pressure line will rise to approx. 400 kPa (4 kgf/sq.cm, 57 psi). In this state, check to see that there are no leaks from any part of the fuel system. NOTICE: Always pinch the hose. Avoid bending as it may cause to hose to crack. Page 2442 Engine Control Module: Testing and Inspection Related Diagnostic Procedures 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 (Making: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 904 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Diagnostic Trouble Code Tests and Associated Procedures Idle Speed/Throttle Actuator - Electronic: Diagnostic Trouble Code Tests and Associated Procedures 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. DETECTING CONDITION WIRING DIAGRAM Page 4154 Finding A Short Circuit 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: 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) Voltage Check Page 4340 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 421 Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation Ford Made System CIRCUIT DESCRIPTION The vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. For each rotation of the shaft, the vehicle speed sensor sends a signal through the combination meter to the cruise control ECU (See the illustration above). The ECU calculates the vehicle speed from this pulse frequency. Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 568 Finding A Short Circuit 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: 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) Voltage Check Page 2896 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 1727 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 768 Page 332 Brake Switch (Cruise Control): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Front Wheel Fastener: Service and Repair Front HUB BOLT REPLACEMENT 1. Remove front wheel. 2. Remove brake caliper and disc. 3. Remove hub bolt. Using Special Service Tool (SST), remove the hub bolt. 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 brake disc and caliper. 6. Install front wheel. Torque: 110 Nm (83 ft. lbs.) Page 958 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3069 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3360 Position Of Parts In Instrument Panel (1 Of 2) (Fig 30) Page 1009 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 3357 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 24) Parts Location Parts Location Page 600 Key to Diagrams Power Window Page 2067 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. (f) 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. 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. (g) Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. (h) Install the intake air connector. (i) Install the air cleaner cap and MAF meter assembly. Diagram Information and Instructions Overdrive Indicator Lamp: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3564 Page 1517 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3882 Pinion Bearing: Application and ID Less Locking Differential Drive Pinion Bearing Adjusting Washer Thickness: 87 ......................................................................................................................................................... .......................................... 1.87 mm (0.0736 inch) 88 ......................................................................... .......................................................................................................................... 1.88 mm (0.0740 inch) 89 ................................................................................................................................................ ................................................... 1.89 mm (0.0744 inch) 90 ................................................................ ................................................................................................................................... 1.90 mm (0.0748 inch) 91 ................................................................................................................................... ................................................................ 1.91 mm (0.0752 inch) 92 ................................................... ................................................................................................................................................ 1.92 mm (0.0756 inch) 93 ............................................................................................................................ ....................................................................... 1.93 mm (0.0760 inch) 94 ............................................ ....................................................................................................................................................... 1.94 mm (0.0764 inch) 95 .................................................................................................................... ............................................................................... 1.95 mm (0.0768 inch) 96 .................................... .............................................................................................................................................................. . 1.96 mm (0.0772 inch) 97 .................................................................................................................. ................................................................................. 1.97 mm (0.0776 inch) 98 .................................. .............................................................................................................................................................. ... 1.98 mm (0.0780 inch) 99 ................................................................................................................ ................................................................................... 1.99 mm (0.0783 inch) 00 ................................ .............................................................................................................................................................. ..... 2.00 mm (0.0787 inch) 01 .............................................................................................................. ..................................................................................... 2.01 mm (0.0791 inch) 02 .............................. .............................................................................................................................................................. ....... 2.02 mm (0.0795 inch) 03 ............................................................................................................ ....................................................................................... 2.03 mm (0.0799 inch) 04 ............................ .............................................................................................................................................................. ......... 2.04 mm (0.0803 inch) 05 .......................................................................................................... ......................................................................................... 2.05 mm (0.0807 inch) 06 .......................... .............................................................................................................................................................. ........... 2.06 mm (0.0811 inch) 07 ........................................................................................................ ........................................................................................... 2.07 mm (0.0815 inch) 08 ........................ .............................................................................................................................................................. ............. 2.08 mm (0.0819 inch) 09 ...................................................................................................... ............................................................................................. 2.09 mm (0.0823 inch) 10 ...................... .............................................................................................................................................................. ............... 2.10 mm (0.0827 inch) 11 .................................................................................................... ............................................................................................... 2.11 mm (0.0831 inch) 12 .................... .............................................................................................................................................................. ................. 2.12 mm (0.0835 inch) 13 .................................................................................................. ................................................................................................. 2.13 mm (0.0839 inch) 14 .................. .............................................................................................................................................................. ................... 2.14 mm (0.0843 inch) 15 ................................................................................................ ................................................................................................... 2.15 mm (0.0846 inch) 16 ................ .............................................................................................................................................................. ..................... 2.16 mm (0.0850 inch) 17 .............................................................................................. ..................................................................................................... 2.17 mm (0.0854 inch) 18 .............. .............................................................................................................................................................. ....................... 2.18 mm (0.0858 inch) 19 ............................................................................................ ....................................................................................................... 2.19 mm (0.0862 inch) 20 ............ .............................................................................................................................................................. ......................... 2.20 mm (0.0866 inch) 21 .......................................................................................... ......................................................................................................... 2.21 mm (0.0870 inch) 22 .......... .............................................................................................................................................................. ........................... 2.22 mm (0.0874 inch) 23 ........................................................................................ ........................................................................................................... 2.23 mm (0.0878 inch) 24 ........ .............................................................................................................................................................. ............................. 2.24 mm (0.0882 inch) 25 ...................................................................................... ............................................................................................................. 2.25 mm (0.0866 inch) 26 ...... .............................................................................................................................................................. ............................... 2.26 mm (0.0890 inch) 27 .................................................................................... ............................................................................................................... 2.27 mm (0.0894 inch) 28 .... .............................................................................................................................................................. ................................. 2.28 mm (0.0898 inch) Diagrams Page 1684 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Page 3667 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 3188 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4322 Ground Points 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. How to Read Power Source Page 3614 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1680 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2695 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 985 b. Adjust the camber and caster by front and/or rear adjusting cams (See adjustment chart). HINT: Try to adjust the camber and caster to the center of the specified values. c. How to read adjustment chart. 1. Find the wheel alignment standard value applicable for the particular model. 2. Mark the selected standard value on the adjustment chart. Example: Camber: 0°10'(0.17°) Caster: 1°40' (1.67°) Page 2291 Key to Diagrams Power Window Page 1788 O2S Application Table O2S Failure Threshold Charts Page 3085 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1720 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 3219 Page 986 3. Mark the alignment value measured when the vehicle was non-loaded on the adjustment chart. Example: Camber: -0° 10' (-0.17°) Caster: 1°40' (1.67°) 4. As shown in the chart, read the distance from the measured value to the standard value, and adjust the front and/or rear adjusting cams accordingly. Example: Front cam: - (Shorter) 2.8 Rear cam: - (Shorter) 2.8 d. Torque the front and/or rear adjusting cam nuts. Torque: 130 Nm (1,325 kgf-cm, 96 ft. lbs.) Measuring Point Reference 5. INSPECT TOE-IN Toe-in: If the toe-in is not within the specified value, adjust the rack ends. 6. ADJUST TOE-IN AND WHEEL ANGLE HINT: First, check or adjust the lengths of the rack ends, then adjust the toe-in. Rack end length difference: 1.5 mm (0.059 inch) or less a. Remove the 2 clips. Page 1594 Chart 2 Of 2 Page 4431 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4777 20. DO HOLD-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminal 50 and the switch body. If there is no continuity, replace the magnetic switch. Page 3515 No. 52 .................................................................................................................................................. .............................................. 4.6 mm (0.181 inch) No. 53 .................................................................. .............................................................................................................................. 4.4 mm (0.173 inch) No. 54 ......................................................................................................................................... ....................................................... 4.2 mm (0.165 inch) No. 55 ......................................................... ....................................................................................................................................... 4.0 mm (0.157 inch) Testing and Inspection Leak Detection Solenoid: Testing and Inspection INSPECTION 1. REMOVE VSV (a) Disconnect the connector and 3 EVAP hoses from the VSV (b) Remove the bolt and VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 37 - 44 ohms at 20°C (68°F) If there is no continuity, replace the VSV. 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. 4. INSPECT VSV OPERATION (a) Check that air flows from ports E to P and does not flow from ports E to F. Page 2099 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3728 Key to Diagrams Power Window Page 3952 Drive/Propeller Shaft: Service and Repair HINT: Pre runner is the models described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB REMOVAL Page 3017 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4664 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3591 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3284 Finding A Short Circuit 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: 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) Voltage Check Page 2297 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3805 Page 4133 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Service and Repair Cylinder Head Gasket: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 1877 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 326 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2021 Key to Diagrams Power Window Page 641 CHART 11 Valve Body Assembly Page 1049 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 ± 25 lbf Used belt: 100 ± 25 lbf 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Page 1173 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Page 4875 Finding A Short Circuit 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: 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) Voltage Check Page 2885 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3876 Fluid - Differential: Fluid Type Specifications DIFFERENTIAL OIL API GL - 5 Hypoid Gear Oil: Above - 18° C (0° F) ............................................. ................................................................................................................................................. SAE 90W Below - 18° C (0° F) .................................................................................................................... ...................................................... SAE 80W - 90 or 80W Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid .............................................................................................................................................. ............................................................ 2.6L (2.7 Qt) Page 1400 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 1761 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3543 Fluid Pump: Specifications Tightening Specifications Stator Shaft X Oil Pump Body ................................................................................................................................................ 10 Nm (100 kg-cm, 7 ft. lbs.) Oil Pump X Transmission Case ............................................................................................................................................. 22 Nm (220 kg-cm, 16 ft. lbs.) Page 4559 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4312 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4873 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1118 NOTICE: Check that the valve of the SST is in the open position. d. Bleed the power steering system. e. Start the engine and run it at idle. f. Turn the steering wheel from lock to lock several times to boost fluid temperature. Fluid temperature: 80°C (176°F) g. With the engine idling, close the valve of the SST and observe the reading on the SST Minimum fluid pressure: 8,336 kPa (85 kgf/cm2,1,209 psi) NOTICE: ^ Do not keep the valve closed for more than 10 seconds. ^ Do not let the fluid temperature become too high. h. With the engine idling, open the valve fully. i. 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. Page 3234 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Service and Repair Universal Joint: Service and Repair REPLACEMENT NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. 1. PLACE MATCHMARKS ON SHAFT AND YOKE 2. TMC made: REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using 2 screwdrivers, remove the 4 snap rings from the grooves. 3. DANA made: REMOVE SNAP RING a. Using a brass bar and hammer, slightly tap in the bearing outer races. b. Using needle nose pliers, remove the 4 snap rings from the grooves. 4. REMOVE SPIDER BEARING a. Using SST, push out the bearing from the propeller shaft. SST 09332-25010 HINT: Sufficiently raise the part indicated by "A" so that it does not come into contact with the bearing. b. Clamp the bearing outer race in a vise and tap off the propeller shaft with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. Page 2118 Key to Diagrams Power Window Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 804 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1891 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2379 CHART 20 Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness and Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Ground Points Ground Points Page 4226 Key to Diagrams Power Window Page 3663 Step 2 Step 3 INSPECTION PROCEDURE Page 373 Step 2 Step 3 Step 4 Page 792 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 3579 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Page 520 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 239 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3824 Page 2108 Air Flow Meter/Sensor: Description and Operation 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. Page 558 Ground Points 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. How to Read Power Source Page 4241 Step 1 Page 461 Key Reminder And Seat Belt Warning Page 408 Key to Diagrams Power Window Page 4296 ABS Light: Testing and Inspection 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 to make the ABS warning light blink and output the DTC. WIRING DIAGRAM Step 1 Step 2 Page 2682 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2333 Knock Sensor: Description and Operation 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. Service and Repair Valve Guide: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 2632 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4562 Finding A Short Circuit 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: 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) Voltage Check Page 1330 Page 4069 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 526 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 762 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2700 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4266 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 4023 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Electronically Controlled Transmission And A/T Indicator-Connectors Page 1222 Crankshaft: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Testing and Inspection Power Steering Pressure Switch: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF. 2. CHECK IDLE-UP. a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 3771 Shift Solenoid: Electrical Diagrams Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4388 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4263 Finding A Short Circuit 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: 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) Voltage Check Locations Fuse Block: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 3568 Step 1 Page 2879 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1804 CHART 22 Page 348 Step 2 Step 3 Page 39 Step 2 Step 3 INSPECTION PROCEDURE ECU Power Source Circuit (Inspection 2) ECU Power Source Circuit (2) Page 2431 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3080 (d) Remove the 2 bolts, 2 nuts and disconnect the throttle body from the air intake chamber. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (e) Remove the throttle body gasket. HINT: At the time of installation, please refer to the following items. Use a new gasket. (f) Disconnect the water bypass hoses from the throttle body and remove the throttle body. 7. REMOVE AIR HOSE FROM IAC VALVE INSTALLATION Installation is in the reverse order of removal. Page 3374 Electronically Controlled Transmission (Part 2 Of 3) Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 1647 Ground Points 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. How to Read Power Source Page 1771 Applicable Vehicles Page 2367 CHART 1 Page 4313 Finding A Short Circuit 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: 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) Voltage Check Page 1979 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3406 Ground Points 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. How to Read Power Source Page 4647 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4642 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4627 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4532 Brake Caliper: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Remove cylinder boot set rings and boots. Using a screwdriver, remove the 4 cylinder boot set rings and boots. 2. Remove pistons from cylinder. a. Prepare the wooden plate to hold the pistons. b. Place the plate between the pistons and insert a pad at one side. Page 382 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4014 VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with Shift Lever at except 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at except L position +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Location Of Splice Points (Fig 38) System Outline Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 Page 2299 Finding A Short Circuit 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: 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) Voltage Check Page 1986 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 3355 Junction Block and Wire Harness Connector Locations-J/B No.1 Lower Finish Panel (Fig 20) Page 72 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2634 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1760 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. A/T.P. (Automatic Transmission Parking) Indicator Circuit Shift Indicator: Description and Operation A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. Page 3136 Key to Diagrams Power Window Page 2507 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1792 CHART 7 Page 643 CHART 14 Locations Horn Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2229 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 304 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 834 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 1696 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3991 Overdrive Indicator Lamp: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 1745 Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3931 Seals and Gaskets: Service and Repair For Axle Shaft Seal service and repair, refer to Axle Shaft, Conventional Fixed/Floating / Service and Repair. Page 2434 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4098 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 621 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3235 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2673 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1938 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4082 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Locations Passenger Airbag Cutoff Switch Location Page 1134 Loosen/Tighten Bleeder Plug 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) 11 Nm (8 ft. lbs.) 5. Repeat procedure for each wheel. 6. Bleed Load Sensing Proportioning & By-Pass Valve (LSP & BV). LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Page 26 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 699 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Specifications Accumulator: Specifications Accumulator Spring Supra: Truck, 4 Runner, T100: Previa: Page 2184 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4591 a. Remove the 4 nuts, 3-way and check valve bracket. Torque: 13 Nm (9 ft. lbs.) b. Pull out the master cylinder and gasket. INSTALLATION Installation is in the reverse order of removal. 1. Before installation, adjust length of brake booster push rod. a. Install a new gasket on the master cylinder. Set SST On Gasket b. Set the SST 09737-00010 on the gasket, and lower the pin until its tip slightly touches the piston. c. Turn the (SST) upside down, and set it on the booster. d. Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 inch) e. Adjust the booster push rod length until the push rod lightly touches the pin head. 2. After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. 3. Check and adjust brake pedal. Page 2564 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 252 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2160 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 664 Page 598 Ground Points 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. How to Read Power Source Locations Overdrive Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 712 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4196 Shift Indicator: Description and Operation Electronically Controlled Transmission and A/T Indicator Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Page 4178 Position Of Parts In Instrument Panel (1 Of 2) (Fig 30) Page 1538 Water Pump: Service and Repair Page 4650 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2576 Knock Sensor: Description and Operation 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. Page 1521 Finding A Short Circuit 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: 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) Voltage Check Page 2552 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3961 c. Install the 2 removed bearing outer races to the spider. d. Using SST, push out the bearing from the yoke. SST 09332-25010 e. Clamp the outer bearing race in a vise and tap off the yoke with a hammer. HINT: Remove the bearing on the opposite side in the same procedure. 5. SELECT SPIDER BEARING Select the bearing according to whether or not there is a drill mark on the yoke section. 6. INSTALL SPIDER BEARING a. Apply MP grease to a new spider and bearings. NOTICE: Be careful not to apply too much grease. b. Align the matchmarks on the yoke and shaft. c. Fit the spider into the yoke. d. Using SST, install new bearings on the spider. Page 3159 Ignition Coil: Service and Repair REMOVAL 1. REMOVE AIR CLEANER HOSE 2. DISCONNECT HIGH-TENSION CORDS FROM IGNITION COILS 3. REMOVE IGNITION COILS (a) Disconnect the 2 connectors from the ignition coils. (b) Remove the 4 bolts and 2 ignition coils from the bracket. Torque: 10 N.m (100 kgf.cm, 7 ft.lbf) HINT: Arrange the ignition coils in correct order. INSTALLATION Installation is in the reverse order of removal. Page 122 Engine Control Module: Connector Views Chart 1 Of 2 Page 3909 7. 3RZ-FE, 5VZ-FE W/ Diff. lock: REMOVE FRONT BEARING OUTER RACE AND OIL STORAGE RING a. Using SST, remove the front bearing outer race. SST 09308-00010 b. Using a screwdriver, bend the oil storage ring and remove it. 8. REMOVE BEARING SPACER a. 3RZ-FE, 5VZ-FE w/o Diff. lock: Remove the 2 washers. b. Remove the bearing spacer. 9. INSTALL NEW BEARING SPACER a. Install a new bearing spacer. b. 3RZ-FE, 5VZ-FE w/o Diff. lock: Install the 2 washers. 10. 3RZ-FE, 5VZ-FE w/ Diff. lock: INSTALL OIL STORAGE RING AND FRONT BEARING OUTER RACE a. Using SST and a hammer, install a new oil storage ring. SST 09316-60011 (09316-00011, 09316-00021) b. Using SST and a hammer, install the front bearing outer race. SST 09316-60011 (09316-00011, 09316-00021) 11. INSTALL FRONT BEARING a. Place the front bearing. b. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: Place the oil slinger. c. Using SST and the companion flange, install the front bearing then remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 12. INSTALL NEW OIL SEAL Page 2087 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Diagram Information and Instructions Brake Fluid Pump: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Testing and Inspection Refrigerant Pressure Sensor / Switch: Testing and Inspection 1. SET ON MANIFOLD GAUGE SET 2. REMOVE GLOVE COMPARTMENT DOOR 3. DISCONNECT CONNECTOR FROM COOLING UNIT 4. SET VEHICLE IN THESE CONDITIONS: a. Running engine at 2,000 rpm b. Blower speed control switch at HI c. Temperature control lever MAX. COOL d. A/C switch ON 5. INSPECT PRESSURE SWITCH OPERATION a. Connect the positive (+) lead from the ohmmeter to terminal 1 and negative (-) lead to terminal 4. 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. Page 770 Vapor Pressure Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) 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 - 3.6V (3) Apply pressure (1.5 kPa, 15 kgf/sq.cm, 0.2 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 2812 (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 Page 4404 Hydraulic Control Assembly - Antilock Brakes: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3997 Step 1 Step 2 Page 3623 Overdrive Indicator Lamp: Electrical Diagrams Page 1895 Finding A Short Circuit 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: 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) Voltage Check Locations Vehicle Speed Sensor: Locations Vehicle Speed Sensor Location Page 2739 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Specifications Brake Drum: Specifications Inside Diameter: Standard 11.614 in Maximum 11.693 in Drum To Shoe Clearance 0.024 in Page 625 A/F and 02 Sensor Identification Page 3127 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 805 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2848 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1582 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2136 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1829 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2889 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 392 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1546 Catalytic Converter: Service and Repair REPLACEMENT 1. REMOVE CONVERTER (a) Jack up the vehicle. (b) Check that the converter is cool. (c) Remove the bolts and nuts at the front and rear of the converter. (d) Remove the converter and gasket. 2. REINSTALL CONVERTER (a) Place new gaskets on the converter front and rear pipes and connect the converter the exhaust pipes. (b) Torque the bolts and nuts. Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) Page 3632 Step 3 Page 3535 Fluid - A/T: Service and Repair 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 349 Step 4 INSPECTION PROCEDURE Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Locations Page 2933 Page 2502 Ground Points 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. How to Read Power Source Locations Overdrive Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4360 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Testing and Inspection Hazard Warning Switch: Testing and Inspection Reference INSPECT HAZARD WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2241 Ground Points 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. How to Read Power Source Page 1337 b. Remove the 4 bolts and A/C compressor bracket. 7. REMOVE GENERATOR, ADJUSTING BAR AND BRACKET a. Disconnect the generator connector. b. Remove the nut, and disconnect the generator wire and wire clip. c. Remove the lock, pivot bolts and the generator. d. Remove the bolt and adjusting bar. e. Remove the 3 bolts and generator bracket. 8. REMOVE CRANKSHAFT POSITION SENSOR a. Remove the 2 bolts and crankshaft position sensor. b. Remove the O-ring from the crankshaft position sensor. 9. 2WD: REMOVE STIFFENER PLATES Remove the 8 bolts and stiffener plates. 10. REMOVE FLYWHEEL HOUSING UNDER COVER AND DUST SEAL Page 2927 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 570 Page 3658 Page 2462 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4048 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 67 INSPECT DAYTIME RUNNING LIGHT NO.4 RELAY CONTINUITY If continuity is not as specified, replace the relay. Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 565 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3198 Knock Sensor: Description and Operation 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. Page 2747 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 2338 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4751 a. Using SST, remove the bearing covers and bearing. SST 09820-00021 NOTE: Be careful not to damage the fan. b. Place the bearing cover on the rotor. c. Using SST and a press, press in a new bearing SST 09820-00030 d. Using SST, push in the bearing cover. SST 09285-76010 Page 2449 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2612 CHART 20 Page 2356 Engine Bank Identification Page 4866 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 29) Page 3711 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 2839 Ground Points 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. How to Read Power Source Page 2213 Starter Signal: Testing and Inspection 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 id mainly used to increase the fuel injection volume for the starting injection control and after-start injection control. WIRING DIAGRAM INSPECTION PROCEDURE HINT: This diagnostic chart is based on the premise that the engine is cranked normally. If the engine is not ¢4mcranked, proceed to the problem symptoms table. Step 1 Page 956 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4161 Step 1 Page 1637 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2263 Ground Points 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. How to Read Power Source Page 3454 Transmission Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2365 Intake Manifold Intake Manifold: Specifications Intake Manifold DIMENSIONS Warpage (Maximum) ............................................................................................................................................................. 0.20 mm (0.0078 inch) TIGHTENING SPECIFICATIONS Intake Manifold To Cylinder Head ................................................................................................................................................. 29 Nm (22 ft. lbs.) Intake Chamber Stay To Air Intake Chamber ................................................................................................................................. 20 Nm (15 ft. lbs.) Intake Chamber Stay To LH Engine Mount Bracket ....................................................................................................................... 20 Nm (15 ft. lbs.) Page 1652 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3391 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2386 CHART 24 Page 1736 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Front Planetary Gear Page 2737 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1656 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1933 Key to Diagrams Power Window Page 632 Page 701 Finding A Short Circuit 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: 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) Voltage Check Page 763 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1042 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 3303 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3087 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2615 CHART 22 Page 3788 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Specifications Axle Shaft: Specifications Rear Axle Shaft: Bearing Backlash: Maximum ............................................................................................................................................. ........................................ 0.7 mm (0.028 inch) Deviation: Maximum ............................................................................................................................................. ...................................... 0.1 mm (0.0039 inch) Shaft Runout: Maximum ............................................................................................................................................. ........................................ 2.0 mm (0.079 inch) Flange Runout: Maximum ............................................................................................................................................. ........................................ 0.1 mm (0.004 inch) Page 2492 Page 258 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4365 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 789 Page 4670 Finding A Short Circuit 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: 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) Voltage Check Page 3588 VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with Shift Lever at except 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at except L position +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Location Of Splice Points (Fig 38) System Outline Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 Page 3557 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3280 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1208 Connecting Rod Bearing: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 3911 Torque: 2RZ-FE: 108 Nm (1,100 kgf-cm, 80 ft. lbs.) 3RZ-FE, 5VZ-FE w/o Diff. lock: 147 Nm (1,500 kgf-cm, 109 ft. lbs.) 3RZ-FE, 5VZ-FE w/ Diff. lock: 196 Nm (2,000 kgf-cm, 145 ft. lbs.) 14. ADJUST DRIVE PINION PRELOAD 15. STAKE DRIVE PINION NUT 16. CONNECT REAR PROPELLER SHAFT 17. FILL DIFFERENTIAL WITH HYPOID GEAR OIL Torque: 49 Nm (500 kgf-cm, 39 ft. lbs.) Oil type: Hypoid gear oil API GL-5 Recommended oil viscosity: Above - 18°C (O°F) SAE 90 Below - 18°C (0°F) SAE 80W or 80W - 90 Capacity Page 4347 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1712 Ground Points 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. How to Read Power Source Page 3654 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4620 Key to Diagrams Power Window Page 1513 Key to Diagrams Power Window Page 96 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1714 Key to Diagrams Power Window Page 20 ABS Main Relay: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. Fill Brake Reservoir 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 brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat b) and c) 3 or 4 times. 3. Connect vinyl tube to brake caliper or wheel cylinder bleeder plug. Insert other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. Page 501 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1698 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3023 Fuel Pump Relay: Testing and Inspection INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY (a) Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION (a) Apply battery positive voltage across terminals STA and E1. (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. (c) Apply battery positive voltage across terminals +B and FC. (d) Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 394 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4111 Transmission Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 1983 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2589 Engine Bank Identification Page 2501 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4257 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3016 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3354 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Page 996 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 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 - Injectors (n) Remove the TOYOTA hand-held tester. (o) Start the engine. (p) Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kgf/sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Stop the engine. (r) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (s) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (t) Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 2172 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 521 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3769 Finding A Short Circuit 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: 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) Voltage Check Page 3370 Finding A Short Circuit 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: 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) Voltage Check Page 4182 no continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Page 1590 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1447 Key to Diagrams Power Window Page 2310 - Transmission in neutral position (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed are kept at 1,000 - 1,500 rpm for 5 seconds, check that they return to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST SST 09843-18020 Page 2391 CHART 27 Page 3306 Key to Diagrams Power Window Page 406 Ground Points 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. How to Read Power Source Page 571 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 3119 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1845 Ground Points 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. How to Read Power Source Page 1040 Testing and Inspection Page 550 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Locations Starter Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2686 Page 3347 Step 3 Testing and Inspection Daytime Running Lamp Relay: Testing and Inspection Terminal Identification INSPECT DAYTIME RUNNING LIGHT RELAY CIRCUIT Disconnect the connector from the relay and inspect the connector on the wire harness side. If circuit is as specified, perform inspections. Electrical - SRS And HV Wiring Repairs Battery System, Hybrid Drive: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 573 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 4259 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4174 Locations-J/B No.3 Behind The Instrument Panel Left (Fig 22) Page 965 Service and Repair Valve Seat: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 3534 Fluid - A/T: Testing and Inspection 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 3138 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1801 CHART 20 Page 955 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3727 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3412 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3519 Page 3064 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Locations Fusible Link: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 79 Headlamp Relay: Testing and Inspection INSPECT HEADLIGHT CONTROL RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 1898 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Locations Overdrive Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness and Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Ground Points Ground Points Page 3710 Page 2925 Fuel Injector: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1346 HINT: If necessary, install the gear with Special Service Tool (SST). (SST) 09636-20010 8. INSTALL NO.1 TIMING CHAIN AND CAMSHAFT TIMING GEAR a. Align the timing mark between the mark link of the No.1 timing chain, and install the No.1 timing chain to the timing gear. b. Align the timing mark of the crankshaft timing gear with the mark link of the No.1 timing chain and install the No.1 timing chain. c. Tie the No.1 timing chain with a cord as shown in the illustration, and make sure it doesn't come loose. 9. INSTALL TIMING CHAIN COVER a. Install 3 new gaskets to the cylinder block and water bypass pipe. b. Install the timing chain cover with the 9 bolts and 2 nuts. Torque: Bolt: 12 mm head A: 20 Nm (200 kgf.cm,14 ft. lbs.) 12 mm head B: 24.5 Nm (250 kgf.cm,18 ft. lbs.) 14 mm head: 44 Nm (440 kgf.cm, 32 ft. lbs.) Nut: 20 Nm (200 kgf.cm, 14 ft. lbs.) Page 2565 Key to Diagrams Power Window Page 2931 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. A/T.P. (Automatic Transmission Parking) Indicator Circuit Shift Indicator: Description and Operation A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. Page 2609 CHART 15 Page 3213 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 927 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 128 Step 2 Step 3 Step 4 Step 5 Page 4662 Key to Diagrams Power Window Page 3787 Ground Points 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. How to Read Power Source Page 4072 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Overdrive Indicator Lamp: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2303 Idle Speed/Throttle Actuator - Electronic: Description and Operation 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. Page 3445 Finding A Short Circuit 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: 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) Voltage Check Page 460 Key Reminder And Seat Belt Warning-Connectors Page 820 Key to Diagrams Power Window Page 1485 Radiator: Diagrams Page 782 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 833 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Page 2100 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3408 Key to Diagrams Power Window Page 4883 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2512 Finding A Short Circuit 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: 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) Voltage Check Page 1824 Key to Diagrams Power Window Page 2684 Finding A Short Circuit 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: 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) Voltage Check Page 849 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Testing and Inspection Heater Core: Testing and Inspection INSPECT FINS FOR BLOCKAGE If the fins are clogged, clean them with compressed air. Page 2339 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1676 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3209 Key to Diagrams Power Window Specifications Planetary Gears: Specifications Front Planetary Gear Maximum Inside Diameter .............................................................................................................................................................. 24.08 mm (0.9480 inch) Planetary Pinion Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. ............................................................................................................................ 1.0 mm (0.0394 inch) Planetary Sun Gear Sun Gear Bushing Inside Diameter, Maximum ............................................................................................................................... 27.08 mm (1.0661 inch) Rear Planetary Gear Planetary Pinion Gear Thrust Clearance Standard .............................................................................................................................................. .................. 0.20 - 0.60 mm (0.0079 - 0.0236 inch) Maximum ............................................................. .......................................................................................................................... 1.00 mm (0.0394 inch) Specifications Crankshaft: Specifications Crankshaft Thrust Clearance Standard 0.020-0.220 mm Maximum 0.30 mm Thrust Washer Thickness 2.440-2.490 mm Crankshaft Runout Maximum Circle Runout 0.03 mm Main Journal Diameter No.3 - Standard 59.981-59.994 mm Others - Standard 59.987-60.000 mm No. 3 - U/S 0.25 59.740-59.750 mm Others - U/S 0.25 59.745-59.755 mm Crank Pin Diameter Standard 52.987-53.000 mm U/S 0.25 52.745-52.755 mm Main Journal and Crank Pin Maximum Taper 0.005 mm Maximum Out-of-Round 0.005 mm Page 3924 9. REPLACE OIL DEFLECTOR a. Using a brass bar and hammer, remove the hub bolts, oil deflector and gasket. b. Position a new gasket on the axle shaft and install a washer and nut to a new hub bolt, as shown in the illustration, and install the hub bolt by torquing the nut. 10. INSTALL REAR AXLE SHAFT IN BACKING PLATE a. Coat a new oil seal lip with MP grease. b. Install the backing plate and bearing retainer on the rear axle shaft. c. Using SST and a press, install the rear axle shaft into the backing plate. SST 09316-60011 (09316-00051) d. Using snap ring expander, install a new snap ring. 11. w/ ABS: INSTALL ABS SPEED SENSOR ROTOR AND BEARING RETAINER (DIFFERENTIAL SIDE) Using SST and a press, install a new sensor rotor and new bearing retainer to the axle shaft. SST 09316-60011 (09316-00051) Standard length: 122.2 ± 1.0 mm (4.811 ± 0.039 inch) 12. REPLACE OIL SEAL (INNER SIDE) a. Using SST, remove the oil seal. SST 09308-00010 Service and Repair Extension Housing: Service and Repair ON-VEHICLE REPAIR 1. REMOVE PROPELLER SHAFT 2. REMOVE REAR OIL SEAL NOTICE: Clean the extension housing before removing the oil seal. Using SST, remove the oil seal. SST 09308 - 10010 3. INSTALL NEW OIL SEAL a. Using SST and a hammer, carefully drive the oil seal in as far as it will go. b. Coat the lip of a new oil seal with MP grease. SST 09325 - 40010 4. INSTALL PROPELLER SHAFT 5. CHECK FLUID LEVEL Testing and Inspection Headlamp Dimmer Switch: Testing and Inspection INSPECT HEADLIGHT DIMMER SWITCH CONTINUITY If continuity is not as specified, replace the switch. Locations Page 2468 Finding A Short Circuit 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: 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) Voltage Check Page 3260 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1717 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2997 Finding A Short Circuit 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: 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) Voltage Check Diagram Information and Instructions Overdrive Indicator Lamp: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2577 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 2002 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 278 Key to Diagrams Power Window Page 2288 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 243 Acceleration/Deceleration Sensor: Description and Operation CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions¢4mtions abnormally. The ECU cuts off current to the ABS control (solenoid) relay and prohibit ABS control¢0m. Page 967 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 3662 Step 1 Page 3426 Step 1 Step 2 Page 27 Page 3501 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.). 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. Page 3312 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 446 Locations-J/B No.1 Lower Finish Panel (Fig 20) Page 3470 Shift Solenoid: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3442 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3745 Transmission Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2414 Oxygen Sensor: Testing and Inspection INSPECTION INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the heated oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohms at 20°C (68°F) Bank 1 Sensor 2: 11 - 16 ohms at 20°C (68°F) if resistance is not as specified, replace the heated oxygen sensor. (c) Reconnect the heated oxygen sensor connector. Page 4667 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1953 Ground Points 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. How to Read Power Source Page 802 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3147 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 3437 Key to Diagrams Power Window Page 2853 Vapor Pressure Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) 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 - 3.6V (3) Apply pressure (1.5 kPa, 15 kgf/sq.cm, 0.2 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V (d) Reconnect the vacuum hose to the vapor pressure sensor. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2183 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1756 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4123 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3925 b. Using SST and a hammer, install a new oil seal. SST 09950-60020 (09951-00710), 09950-70010 (09951-07150) c. Coat a new oil seal lip with MP grease. INSTALLATION Installation is in the reverse order of removal. HINT: After installation, bleed the brake system and check the ABS speed sensor signal. Page 736 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Description and Operation Malfunction Indicator Lamp: Description and Operation 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 Diagnostic Trouble Code (DTC) prescribed by SAE J2012 are recorded in the ECM memory. If the malfunction has been repaired, the MIL goes off automatically but the DTCs remain recorded in the ECM memory. Testing and Inspection Power Window Switch: Testing and Inspection INSPECT POWER WINDOW MASTER SWITCH CONTINUITY Driver's switch(Window unlock): Driver's switch(Window lock): Passenger's switch(Window unlock): Passenger's switch(Window lock): If continuity is not as specified, replace the switch. INSPECT POWER WINDOW SWITCH CONTINUITY If continuity is not as specified, replace the switch. Using an ammeter: INSPECT ONE TOUCH POWER WINDOW SYSTEM Page 4399 Ground Points 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. How to Read Power Source Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2937 Fuel Injector: Testing and Inspection On-Vehicle 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 normal operating noise in proportion to engine speed. (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. 2. INSPECT INJECTOR RESISTANCE (a) Remove the throttle body. (b) Disconnect the injector connectors. (c) Using an ohmmeter, measure the resistance between the terminals. Resistance: 12 - 16 ohms at 20°C (68°F) If the resistance is not as specified, replace the injector. (d) Reconnect the injector connectors. (e) Reinstall the throttle body. Page 3139 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Testing and Inspection Turn Signal Switch: Testing and Inspection INSPECT TURN SIGNAL SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4888 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1846 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 498 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1606 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 357 Key to Diagrams Power Window Page 1943 Page 250 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3573 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 4185 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 744 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 2992 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2768 Vehicle Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3963 a. Check that the spider bearing moves smoothly. b. Check the spider bearing axial play. Maximum bearing axial play: 0.05 mm (0.0020 inch) HINT: ^ Install new spider bearings on the shaft side in the procedure described above. ^ When replacing the propeller shaft spider on pre runner and rear propeller shaft spider on 4WD vehicles, be sure that the grease fitting assembly hole is facing in the direction shown in the illustration on the next page. Page 2292 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 932 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 1057 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 1704 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 3719 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 3659 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 3744 Page 1385 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. (f) 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. 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. (g) Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. (h) Install the intake air connector. (i) Install the air cleaner cap and MAF meter assembly. Page 2124 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3313 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 167 Page 3468 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 808 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2604 CHART 8 CHART 9 Page 2041 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 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 - Injectors (n) Remove the TOYOTA hand-held tester. (o) Start the engine. (p) Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kgf/sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Stop the engine. (r) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (s) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (t) Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 1964 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3706 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 630 Page 2480 Ground Points 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. How to Read Power Source Mechanical Specifications Brake Proportioning/Combination Valve: Mechanical Specifications TORQUE SPECIFICATIONS Load Sensing Proportioning And By-Pass Valve (LSP & BV) To: LSP & BV Bracket ............................................................................................................................... ..................................... 13 Nm (108 inch lbs.) LSP & BV Bracket To: Load Sensing Spring Assembly ...................................................................................................................................................... 18 Nm (13 ft. lbs.) Frame .......................................................................................................................... .................................................................... 29 Nm (22 ft. lbs.) Load Sensing Spring Assembly To: Shackle No.1 ....................................................................................................................................... ............................................ 18 Nm (13 ft. lbs.) Page 165 Finding A Short Circuit 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: 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) Voltage Check Page 4145 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1873 Finding A Short Circuit 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: 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) Voltage Check Page 3990 Page 2030 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4653 Page 4324 Key to Diagrams Power Window Page 2840 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 779 Key to Diagrams Power Window Page 4806 Location Of Splice Points (Fig 38) Page 3815 Page 2961 Fuel Line Inspection 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. Page 3595 Finding A Short Circuit 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: 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) Voltage Check Page 2374 CHART 12 CHART 13 With Locking Differential Pinion Bearing: Application and ID With Locking Differential Drive Pinion Bearing Adjusting Washer Thickness: .............................................................................................................................................................. ......................................... 1.70 mm (0.0669 inch) ............................................................................... ........................................................................................................................ 1.73 mm (0.0681 inch) .............................................................................................................................................................. ......................................... 1.76 mm (0.0693 inch) ............................................................................... ........................................................................................................................ 1.79 mm (0.0705 inch) .............................................................................................................................................................. ......................................... 1.82 mm (0.0717 inch) ............................................................................... ........................................................................................................................ 1.85 mm (0.0728 inch) .............................................................................................................................................................. ......................................... 1.88 mm (0.0740 inch) ............................................................................... ........................................................................................................................ 1.91 mm (0.0752 inch) .............................................................................................................................................................. ......................................... 1.94 mm (0.0764 inch) ............................................................................... ........................................................................................................................ 2.00 mm (0.0787 inch) .............................................................................................................................................................. ......................................... 2.03 mm (0.0799 inch) ............................................................................... ........................................................................................................................ 2.06 mm (0.0811 inch) .............................................................................................................................................................. ......................................... 2.09 mm (0.0823 inch) ............................................................................... ........................................................................................................................ 2.12 mm (0.0835 inch) .............................................................................................................................................................. ......................................... 2.15 mm (0.0846 inch) ............................................................................... ........................................................................................................................ 2.18 mm (0.0858 inch) .............................................................................................................................................................. ......................................... 2.21 mm (0.0870 inch) ............................................................................... ........................................................................................................................ 2.24 mm (0.0882 inch) .............................................................................................................................................................. ......................................... 2.27 mm (0.0894 inch) ............................................................................... ........................................................................................................................ 2.30 mm (0.0906 inch) .............................................................................................................................................................. ......................................... 2.33 mm (0.0917 inch) Diagram Information and Instructions Cruise Control Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Specifications Piston Ring: Specifications Piston Ring Groove Clearance No.1 0.020-0.070 mm No.2 0.030-0.070 mm Piston Ring Eng Gap No.1 0.300-0.400 mm No.2 0.400-0.500 mm Diagram Information and Instructions ABS Main Relay: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3586 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Relay Blocks Relay Blocks Page 3443 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1657 Finding A Short Circuit 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: 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) Voltage Check Page 4598 Wheel Cylinder: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 214 Power Window Relay: Testing and Inspection INSPECT POWER MAIN RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 781 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3820 Valve Body: Locations Lower Valve Body Page 411 Vehicle Speed Sensor/Transducer - Cruise Control: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Specifications Firing Order: Specifications Firing order: 1-3-4-2 Page 798 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3065 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 163 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3195 Finding A Short Circuit 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: 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) Voltage Check Specifications Fluid Pan: Specifications Oil Pan X Transmission Case .............................................................................................................................................. 7.4 Nm (75 kg-cm, 65 inch lbs.) Page 2859 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 867 Key to Diagrams Power Window Page 2187 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1973 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1864 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 740 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 283 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 282 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3668 O/D OFF indicator light remains ON Page 4476 Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. If necessary, adjust disc runout. a. Remove the hub nuts and disc. Reinstall the disc 1/6 of a turn round 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. b. Repeat a) until the disc has been installed on the 4 remaining hub position. c. If the minimum runout recorded in a) and b) is less than maximum disc runout, install the disc in that position. d. If the minimum runout recorded in a) and b) is greater than maximum disc runout, replace the disc and repeat step 3. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows. Locations Page 1937 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1757 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Locations Headlamp Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Specifications Air Bag Control Module: Specifications Airbag Control Module Mounting Bolts 15 ft.lb Page 1029 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS (a)Disconnect the high-tension cords from the spark plugs. (b) Using a 16 mm plug wrench, remove the spark plug. (c) Using a spark plug cleaner or wire brush, clean the spark plug. (d) Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA (e) Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) (f) Using a 16 mm plug wrench, install the spark plug. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (g) Connect the high-tension cords to the spark plugs. Page 3590 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Removal and Installation Load Compensator: Service and Repair Removal and Installation REMOVAL 1. Disconnect shackle No.2 from bracket. a. Remove the nut and disconnect the shackle No.2. b. Remove the cushion retainer, 2 cushions and collar. Page 2210 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1503 5. When using the radiator cap tester, tilt it more than 30 degrees. 6. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Page 1853 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4831 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 1550 Exhaust Manifold: Testing and Inspection For information regarding the testing and inspection of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Disassembly and Reassembly. Page 2121 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2555 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 497 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4846 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1821 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3217 Finding A Short Circuit 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: 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) Voltage Check Removal and Installation Starter Motor: Service and Repair Removal and Installation ON-VEHICLE INSPECTION NOTE: Before changing the starter, check the following items again: ^ Connector connection ^ Accessory installation, e.g.: theft deterrent system Testing and Inspection Power Steering Pressure Switch: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF. 2. CHECK IDLE-UP. a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 737 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4785 4. REINSTALL TERMINAL KIT PARTS a. Terminal 30: Install these new parts: 1. Insulation paper 2. Terminal insulator (inside) NOTE: Be careful to install the terminal insulator in the correct direction. 3. Contact plate 4. Terminal bolt 5. O-ring 6. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them. HINT: Match the protrusion of the insulator with the indentation of the housing. 7. Wave washer 8. Terminal nut b. Terminal C: Install these new parts: A 1. Terminal insulator (inside) NOTE: Be careful to install the terminal insulator in the correct direction. 2. Contact plate 3. Terminal bolt 4. O-ring 5. Terminal insulator (outside) 6. Wave washer 7. Terminal nut Page 3236 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 973 a. Disconnect the connector of the master switch. b. Connect the positive (+) lead from the ammeter to terminal 4 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 9 on the wire harness side connector. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit breaker operates. If the operation is as specified, replace the master switch. Using an ammeter with a current-measuring probe: INSPECT ONE TOUCH POWER WINDOW SYSTEM a. Remove the master switch with the connector connected. b. Attach a current-measuring probe to terminal 3 of the wire harness. c. Turn the ignition switch ON and set the power window switch in the down position. d. As the window goes down, check that the current increases to approximately 7.0 A. e. Check that the current increases to approximately 14.5 A or more when the window stops going down. HINT: The circuit breaker opens for some 4 - 40 seconds after the window stops going down, so that the check must be done before the circuit Page 4083 Step 1 Step 2 Page 4162 Step 2 Step 3 INSPECTION PROCEDURE Page 2991 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1599 Step 2 Step 3 Step 4 Step 5 Page 1616 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4872 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2457 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2921 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4868 Locations-R/B No.2-Engine Compartment Left (Fig 19) Splice Points Splice Points Page 2513 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 659 CHART 27 Page 1165 Malfunction Indicator Lamp: Testing and Inspection MALFUNCTION INDICATOR LAMP (MIL) CHECK 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. 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. Locations Overdrive Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4164 Step 1 Step 2 Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2438 Chart 2 Of 2 Page 4381 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3264 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 4328 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4561 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2944 Fuel Pressure Regulator: Service and Repair REMOVAL 1. DISCONNECT VACUUM SENSING HOSE FROM FUEL PRESSURE REGULATOR 2. DISCONNECT FUEL RETURN HOSE FROM FUEL PRESSURE REGULATOR HINT: Put a suitable container or shop towel under the pressure regulator. 3. REMOVE FUEL PRESSURE REGULATOR (a) Remove the 2 bolts and fuel pressure regulator. Torque: 8.8 N.m (90 kgf.cm, 78 in.lbf) (b) Remove the O-ring. HINT At the time of installation, please refer to the following items. Use a new O-ring. INSTALLATION Installation is in the reverse order of removal. Page 1828 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2212 Starter Signal: Description and Operation Starter Signal When the engine is cranked, the intake airflow 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. Page 1856 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4126 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4732 8. Select the appropriate model and press the NEXT soft key. 9. Select OEM battery type and press the NEXT soft key. 10. Choose the correct battery (model number and CCA) and press the NEXT soft key. 11. Aim the infrared (IR) temperature measurement sensor at the negative (-) battery post and press the NEXT soft key. Page 4144 Ground Points 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. How to Read Power Source Locations Fuse Block: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3498 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 496 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3363 VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with Shift Lever at except 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at except L position +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Location Of Splice Points (Fig 38) System Outline Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 Page 2529 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2525 Key to Diagrams Power Window A/T - Torque Converter Bolt Installation Precautions Torque Converter: Technical Service Bulletins A/T - Torque Converter Bolt Installation Precautions T-SB-0014-11 February 17, 2011 Torque Converter Bolt Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of the correct torque converter bolts during automatic transmission/transaxle assembly replacement. Incorrect torque converter bolts or missing washers can cause damage to the torque converter assembly. Use the information in this bulletin when installing an automatic transmission/transaxle assembly. NOTE Not all applications will use washers on the torque converter bolts. Warranty Information Installation Procedure ^ When removing torque converter bolts and washers take special care that the same bolts and washers are used when installing the torque converter. ^ Using an incorrect size bolt or washer may cause damage to the torque converter assembly. Page 160 Igniter: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 529 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 4076 Page 236 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 710 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1401 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 2656 Ground Points 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. How to Read Power Source Page 1741 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2901 Fuel: Specifications Fuel Type Unleaded fuel only, Research Octane Number 91 (Octane Rating 87) or higher. Page 2701 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2020 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 531 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 3285 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4124 Key to Diagrams Power Window Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. Fill Brake Reservoir 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 brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat b) and c) 3 or 4 times. 3. Connect vinyl tube to brake caliper or wheel cylinder bleeder plug. Insert other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. Page 4330 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2517 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 1974 Key to Diagrams Power Window Testing and Inspection Catalytic Converter: Testing and Inspection INSPECTION 1. CHECK TWC FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it touches the three-way catalytic converter, repair or replace it. 2. CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3. CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE 4. CHECK HEAT INSULATOR FOR DAMAGE 5. CHECK FOR ADEQUATE CLEARANCE BETWEEN TWC AND HEAT INSULATOR Page 2745 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3725 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4825 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4081 Step 2 Step 3 INSPECTION PROCEDURE Page 734 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 1297 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 1585 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Diagram Information and Instructions Brake Signal: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4005 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Page 4065 Key to Diagrams Power Window Page 2888 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3262 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 825 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1515 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 750 EGR Temperature Sensor: Testing and Inspection INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 K ohms at 50°C (122°F) 11 - 16 K ohms at 100°C (212°F) 2 - 4 K ohms at 150°C (302°F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 668 Ground Points 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. How to Read Power Source Page 507 Air Flow Meter/Sensor: Description and Operation 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. Page 1342 c. Using vernier calipers, measure the timing gear and timing sprocket diameter with the chain. NOTICE: Vernier calipers must contact the chain rollers for measuring. Minimum gear diameter (w/ chain): Camshaft: 113.8 mm (4.480 inch) Crankshaft: 59.4 mm (2.339 inch) 3RZ-FE: Balance shaft: 75.9 mm (2.988 inch) Minimum sprocket diameter (w/ chain): 3RZ-FE: No.2 crankshaft: 96.7 mm (3.807 inch) If the diameter is less than minimum, replace the chain, gears and sprocket. 2. INSPECT CHAIN TENSIONER SLIPPER AND VIBRATION DAMPERS Measure the chain tensioner slipper and vibration damper wears. Maximum wear: 1.0 mm (0.039 inch) If the wear is greater than maximum, replace the slipper and/or dampers. Page 4749 a. Unsolder and remove the brush and spring. b. Run the wire of a new brush through the hole in the brush holder, and insert the spring and brush into the brush holder. c. Solder the brush wire to the brush holder at specified exposed length. Exposed length: 9.5 - 11.5 mm (0.374 - 0.453 in.) d. Check that the brush moves smoothly in the brush holder. e. Cut off the excess wire. f. Apply insulation paint to the soldered area. 8. INSPECT POSITIVE RECTIFIER a. Using an ohmmeter, connect one tester probe to the positive (+) terminal and the other to each rectifier terminal. b. Reverse the polarity of the tester probes and repeat step (a). c. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 9. INSPECT NEGATIVE RECTIFIER a. Using an ohmmeter, connect one tester probe to each negative (-) terminal and the other to each rectifier terminal. Page 853 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 388 Cruise Control Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3168 Key to Diagrams Power Window Diagram Information and Instructions Starter Signal: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2350 Testing and Inspection Power Door Lock Switch: Testing and Inspection INSPECT DRIVER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT PASSENGER'S DOOR LOCK CONTROL SWITCH CONTINUITY If continuity is not as specified, replace the switch. INSPECT DOOR KEY LOCK AND UNLOCK SWITCH CONTINUITY LH: Page 642 CHART 12 CHART 13 Page 2104 Finding A Short Circuit 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: 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) Voltage Check Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4189 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2445 Engine Control Module: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO. 2 PANEL 3. REMOVE ECM (a) Disconnect the 4 ECM connectors. (b) Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 3170 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 23 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4243 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 4609 Vacuum Brake Booster: Testing and Inspection ON-VEHICLE INSPECTION 1. Operating check. a. Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. b. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. Brake Booster Assembly Operation Test 2. Air tightness check. a. 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. Page 1960 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1803 CHART 21 Page 1896 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1832 Finding A Short Circuit 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: 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) Voltage Check Page 1781 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ 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 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 4689 Key to Diagrams Power Window Page 743 Vehicle Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 733 Key to Diagrams Power Window Page 3571 Step 1 Step 2 Page 1985 Page 3801 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 4342 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2353 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 3416 Finding A Short Circuit 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: 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) Voltage Check O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 77 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2550 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1037 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 937 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 500 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2794 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1423 Coolant: Service and Repair REPLACEMENT 1. REPLACE ENGINE COOLANT a. Remove the radiator cap. WARNING: 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 the coolant from the radiator and cylinder drain plugs. (Engine coolant drain plug at the right of cylinder block.) c. Close the drain plugs. Torque: Engine coolant drain plug: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 2. FILL ENGINE COOLANT a. Slowly fill the system with coolant. - Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's directions. - Using coolant which includes more than 50 % ethylene-glycol (but not more than 70 %) is recommended. NOTICE: ^ Do not use an alcohol type coolant. ^ The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Heater): 2WD: M/T: 8.0 liters (8.5 US qts., 7.0 Imp. qts.) A/T: 7.8 liters (8.2 US qts., 6.9 Imp. qts.) 4WD: M/T: 8.3 liters (8.8 US qts., 7.2 Imp. qts.) A/T: 8.2 liters (8.7 US qts., 7.2 Imp. qts.) b. Reinstall the radiator cap. c. Start the engine, and bleed the cooling system. d. If necessary, refill engine coolant into the radiator reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 3208 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2368 CHART 2 CHART 3 CHART 4 Page 4209 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4229 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2797 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3231 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3732 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2469 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3249 Ground Points 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. How to Read Power Source Page 1343 3. 2RZ-FE: INSPECT OIL JET Check the oil for damage or clogging. If necessary, replace the oil jet. 4. INSPECT NO.1 CHAIN TENSIONER 5. 3RZ-FE: INSPECT NO.2 CHAIN TENSIONER a. Inspect the chain tensioner - Check that the plunger moves smoothly when the ratchet pawl is raised with your finger. - Release the ratchet pawl and check that the plunger is locked in place by the ratchet pawl and does not move when pushed with your finger. b. Inspect the oil jet (No.2 chain tensioner). Check the oil jet for damage or clogging. If necessary, replace the oil jet (No.2 chain tensioner). INSTALLATION Page 1817 CHART 30 Page 3358 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 28) Page 4068 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 818 Ground Points 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. How to Read Power Source Page 3335 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 928 Finding A Short Circuit 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: 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) Voltage Check Page 4475 c. Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. 3. Remove piston seals. Using a screwdriver, remove the 4 seals from the cylinder. INSPECTION 1. Measure pad lining thickness. Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. 2. Measure disc thickness. Using a micrometer, measure the disc thickness. Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) If the disc is scored or worn, or if its thickness is less than minimum, repair or replace the disc. 3. Measure disc runout. a. Tighten the disc with the 3 hub nuts. b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Page 2636 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4054 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1159 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 147 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 1789 CHART 1 Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 544 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2760 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 524 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Denso Made System Vehicle Speed Sensor/Transducer - Cruise Control: Description and Operation Denso Made System CIRCUIT DESCRIPTION The signal from the vehicle speed sensor circuit is sent to cruise control ECU as vehicle speed signal. For each rotation of the shaft, the vehicle speed sensor sends a signal through the combination meter to the cruise control ECU (See the following illustration). The ECU calculates the vehicle speed from this pulse frequency. Page 2728 Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1058 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: All Technical Service Bulletins Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Page 4444 Page 3752 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4224 Ground Points 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. How to Read Power Source Page 111 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3429 O/D OFF indicator light remains ON Page 3392 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4437 Wheel Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1719 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 871 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2586 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 2557 Intake Air Temperature Sensor: Description and Operation 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. Figure 1 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. 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 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. Page 3624 Page 4693 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4311 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4408 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 655 CHART 25 Service and Repair Timing Chain Tensioner: Service and Repair For information regarding the service and repair of this compoent and the system that it is a part of please refer to Timing Chain; Service and Repair, Page 755 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2733 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3655 Finding A Short Circuit 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: 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) Voltage Check Page 3698 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2007 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2232 Page 874 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 1671 Key to Diagrams Power Window Diagram Information and Instructions Clutch Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2662 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2665 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4134 Shift Solenoid: Electrical Diagrams Page 3295 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS (a)Disconnect the high-tension cords from the spark plugs. (b) Using a 16 mm plug wrench, remove the spark plug. (c) Using a spark plug cleaner or wire brush, clean the spark plug. (d) Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA (e) Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) (f) Using a 16 mm plug wrench, install the spark plug. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (g) Connect the high-tension cords to the spark plugs. Page 4282 Ground Points 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. How to Read Power Source Page 4063 Ground Points 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. How to Read Power Source Page 3414 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1636 Finding A Short Circuit 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: 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) Voltage Check Specifications Brake Hose/Line: Specifications Brake Line Union Nut .......................................................................................................................... .................................................... 15 Nm (11 ft. lbs.) Page 110 Ground Points 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. How to Read Power Source Diagram Information and Instructions Acceleration/Deceleration Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1183 Wheel Fastener: Service and Repair Rear HUB BOLT REPLACEMENT 1. Remove wheel and brake drum. 2. Remove hub bolt. Using SST, 09650-17011 3. Install hub bolt. Install a washer and nut to a new hub bolt as shown and install the hub bolt with torquing the nut. 4. Install brake drum and wheel. Torque to 110 Nm (83 ft. lbs.) Page 2119 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2704 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 517 Key to Diagrams Power Window Page 4361 Key to Diagrams Power Window Page 4802 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 27) Page 4626 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Diagram Information and Instructions Overdrive Indicator Lamp: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3364 no continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Page 3143 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4496 Brake Pad: Specifications Thickness: Standard 0.453 in Minimum 0.039 in Page 3877 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Page 4801 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 24) Parts Location Parts Location Page 2147 Page 713 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3046 Finding A Short Circuit 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: 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) Voltage Check Removal and Installation Radiator: Service and Repair Removal and Installation Page 2621 Page 1869 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4566 Hydraulic Control Assembly - Antilock Brakes: Description and Operation 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. Fail safe function: If trouble occurs in the ABS solenoid valve circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 627 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ 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 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 1268 Valve Spring Shim: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Valve Clearance; Service and Repair. Page 3814 CHECK BALL DIAMETERS Page 1670 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1931 Ground Points 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. How to Read Power Source Page 692 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 3455 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 4236 Overdrive Switch: Electrical Diagrams Page 161 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Wheel Cylinder: Specifications Bleeder Plug 96 in.lb Wheel Cylinder To Backing Plate 84 in.lb Page 4384 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3560 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 827 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4253 Ground Points 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. How to Read Power Source Page 4341 Ground Points 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. How to Read Power Source Page 2916 Fuel Injector: Capacity Specifications Injector Volume Injector Volume Resistance 12-16 ohms at 68 deg F Volume 69-88 cm3 (34.2-5.4 cu in.) Per 15 seconds Difference Between Injectors 5 cm3 (0.3 cu in.) or less Leakage 1 drop or less per 3 Minutes Page 1592 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1848 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1244 Page 508 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 3220 Igniter: Description and Operation 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 1 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 2 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 power transistors in the igniter cuts off the current to the primary coil in the ignition coil is supplied simultaneously to the two spark plugs via the high-tension cords that are connected to the both ends of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3367 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 623 Page 3371 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1593 Engine Control Module: Connector Views Chart 1 Of 2 Page 2951 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check that the battery positive voltage is above 12 volts. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the union bolt and 2 gaskets and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. (d) Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (e) Wipe off any splattered gasoline. (f) Connect the TOYOTA hand-held tester to the DLC3. (g) Turn the ignition switch ON and 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. (k) Reconnect the negative (-) terminal cable to the battery. (l) Turn the ignition switch ON. (m)Measure the fuel pressure. Fuel pressure: Page 3474 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3466 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3241 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 3583 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 28) Page 2993 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 330 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3066 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 669 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 310 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 314 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 463 Key Reminder Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2235 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Specifications Camshaft Gear/Sprocket: Specifications Camshaft Timing Gear Bolt 73.5 Nm (54 ft.lb) Page 3994 Step 1 Page 3029 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2677 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2681 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4012 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Relay Blocks Relay Blocks Page 578 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3665 Step 1 Step 2 Page 1107 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................... SH Energy Conserving II, SJ Energy Conserving, or ILAC Multigrade Above 0° F (-18°C) .................................. .............................................................................................................................................................. ... 10W-30 All Temperatures ................................................................................................................ .......................................................................................... 5w-30 Page 1762 Finding A Short Circuit 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: 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) Voltage Check Page 3171 Igniter: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Capacity Specifications Engine Oil: Capacity Specifications Engine Oil Refill With Filter ................................................................................................................................... ....................................................................... 5.8 Qt Without Filter ....................................................................................................................................... ........................................................................ 5.0 Qt NOTE: Listed capacities are approximate. Check fluid level after filling. Page 2340 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 2159 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3715 Step 2 Step 3 INSPECTION PROCEDURE Page 4245 Step 3 Page 2780 NOTICE: Never apply more than 93 kPa (0.95 kgf.sq.cm, 13.5 psi) of pressure compressed air to the VSV. (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 Page 2699 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Ford Made System Cruise Control Switch: Testing and Inspection Ford Made System 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 Step 1 O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 3190 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3917 Axle Shaft: Diagrams REAR AXLE SHAFT ASSEMBLY AND RELATED COMPONENTS Page 2852 Vapor Pressure Sensor: Description and Operation 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. Page 145 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3763 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 538 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2602 CHART 5 CHART 6 Page 523 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1469 Heater Core: Service and Repair REMOVAL 1. REMOVE HEATER UNIT 2. REMOVE HEATER RADIATOR a. Remove 3 screws and 3 plates and clamp. b. Pull the radiator upward. INSTALLATION Installation is in the reverse order of removal. Page 2623 Locations Specifications Band Apply Servo: Specifications Second Coast Brake Piston Stroke ..................................................................................................... ................................................................ 1.5 - 3.0 mm (0.059 - 0.118 inch) Piston Rod Length ......... .............................................................................................................................................................. ........ 72.9 mm (2.870 inch) .............................................................................................................................................................. .......................... 71.4 mm (28.11 inch) Page 923 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 168 Igniter: Description and Operation 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 1 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 2 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 power transistors in the igniter cuts off the current to the primary coil in the ignition coil is supplied simultaneously to the two spark plugs via the high-tension cords that are connected to the both ends of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Page 3250 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2488 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4554 Key to Diagrams Power Window Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3176 Finding A Short Circuit 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: 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) Voltage Check Page 1453 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2370 CHART 7 Page 1116 Power Steering Fluid: Service Precautions Use automatic transmission fluid Dexron II or Dexron III. Page 1722 Finding A Short Circuit 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: 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) Voltage Check Page 4661 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Service and Repair Seals and Gaskets: Service and Repair REPLACEMENT HINT: Pre-runner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. DRAIN DIFFERENTIAL OIL 2. DISCONNECT REAR PROPELLER SHAFT 3. REMOVE COMPANION FLANGE Page 3930 The design of the rear axle seal has been changed from a flat face to an angled face for part number 90310-50006 and part number 90310-56002. Installation Procedure Sequoia To properly install Rear Axle Oil Seal part number 90310-56002, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00730-01) - Replacer 73 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Tacoma & Tundra To properly install Rear Axle Oil Seal part number 90310-56006, use the following SSTs and a hammer to install the new oil seal: ^ SST P/N 09950-60020-01 (09951-00710) - Replacer 71 ^ SST P/N 09951-70010-01 (09951-07150-01) - Handle Page 1802 Testing and Inspection Vacuum Check Valve: Testing and Inspection 1. REMOVE CHECK VALVE 2. INSPECT CHECK VALVE (a) Check that air flows from the orange pipe to the black pipe. (b) Check that air does not flow from the black pipe to the orange pipe. If operation is not as specified, replace the check valve. 3. INSTALL CHECK VALVE HINT: Install the check valve with the orange pipe facing the EGR vacuum modulator side. Page 391 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 146 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3186 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 134 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3703 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2306 Step 1 Step 2 Page 2723 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 260 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Locations Fusible Link: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3638 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3057 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 309 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 811 Page 3977 Ground Points 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. How to Read Power Source Page 2861 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 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 - Injectors (n) Remove the TOYOTA hand-held tester. (o) Start the engine. (p) Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kgf/sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Stop the engine. (r) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (s) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (t) Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 1083 Coolant: Service and Repair REPLACEMENT 1. REPLACE ENGINE COOLANT a. Remove the radiator cap. WARNING: 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 the coolant from the radiator and cylinder drain plugs. (Engine coolant drain plug at the right of cylinder block.) c. Close the drain plugs. Torque: Engine coolant drain plug: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 2. FILL ENGINE COOLANT a. Slowly fill the system with coolant. - Use a good brand of ethylene-glycol base coolant and mix it according to the manufacturer's directions. - Using coolant which includes more than 50 % ethylene-glycol (but not more than 70 %) is recommended. NOTICE: ^ Do not use an alcohol type coolant. ^ The coolant should be mixed with demineralized water or distilled water. Capacity (w/ Heater): 2WD: M/T: 8.0 liters (8.5 US qts., 7.0 Imp. qts.) A/T: 7.8 liters (8.2 US qts., 6.9 Imp. qts.) 4WD: M/T: 8.3 liters (8.8 US qts., 7.2 Imp. qts.) A/T: 8.2 liters (8.7 US qts., 7.2 Imp. qts.) b. Reinstall the radiator cap. c. Start the engine, and bleed the cooling system. d. If necessary, refill engine coolant into the radiator reservoir until it is "FULL" line. 3. CHECK ENGINE COOLANT FOR LEAKS Page 2994 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2332 Page 4731 4. Press the NEXT soft key (if applicable) when the HELLO screen appears to proceed to the Main Menu. 5. Choose BATTERY TEST and press the SELECT soft key. 6. Select IN VEHICLE and press the NEXT soft key. 7. Select MODEL and press the NEXT soft key. NOTE: ^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad. ^ "MODEL" and "STOCK#" are linked to custom algorithms and are the most accurate testing procedures. Page 448 Locations-R/B No.2-Engine Compartment Left (Fig 19) Service Hints B 6 BUCKLE SW 1-2: Open with Driver's Seat Belt in use D15 DOOR COURTESY SW LH 1-GROUND: Closed with LH Door open I15-A SEAT BELT WARNING RELAY (INTEGRATION RELAY) 6-GROUND: Approx. 12 Volts with Ignition SW ON 12-GROUND: Always Approx. 12 Volts A-7-GROUND: Always Continuity A-5-GROUND: Continuity with LH Door open A-10-GROUND: Approx. 12 Volts with Ignition Key in Cylinder A-2-GROUND: 0 Volts for 4-8 Seconds with Ignition SW ON and 12 Volts 4-8 Seconds after Ignition SW ON Splice Points Page 3518 Page 2240 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2678 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3111 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3957 c. Install the spacer. d. Using SST to hold the flange, press the bearing into position by tightening down a new nut. SST 09330-00021 Torque: 181 Nm (1,850 kgf cm, 134 ft. lbs.) e. Loosen the nut. f. Torque the nut again. Torque: 69 Nm (700 kgf cm, 51 ft. lbs.) g. Using a chisel and hammer, stake the nut. 3. 3-joint type: CONNECT PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Align the matchmarks on the flanges and connect the flanges with the 4 bolts, washers and nuts. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. b. Torque the nuts. Torque: 74 Nm (750 kgf cm, 54 ft. lbs.) 4. INSERT SLEEVE YOKE INTO PROPELLER SHAFT a. Apply grease to the propeller shaft spline and sleeve yoke sliding surface. Grease: Molybdenum disulfide lithium base chassis grease, NLGI No. 2. b. Install the dust cover to the shaft. c. Align the matchmarks on the yoke and propeller shaft. INSTALLATION Installation is in the reverse order of removal. HINT: ^ Propeller shaft (pre runner) and rear propeller shaft (4WD) of 3-joint type: Center bearing center line and the center bearing housing center line must be adjusted within 0 ± 1 mm (0 ± 0.04 inch) of each other in the vehicles front and rear direction when the vehicle is unloaded. ^ Propeller shaft (pre runner) and rear propeller shaft (4WD) of 3-joint type: When adjusting the center bearing housing center line, it should be perpendicular to the axis of front propeller shaft. ^ With a grease gun, pump grease into each fitting until it begins to flow around the oil seal. Grease: Spiders: Lithium base chassis grease, NLGI No. 2. Sleeve yoke and double cardan joint: Molybdenum disulfide lithium base chassis grease, NLGI No. 2. Specifications Thermostat: Specifications Valve Opening Temperature 80-84°C (176-183°F) Valve Lift 8 mm at 95°C (203°F) Valve Fully Closed Below 40°C (104°F) Diagram Information and Instructions Key Reminder Switch: Diagram Information and Instructions Ground Points Ground Points Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Junction Block and Wire Harness Connector Page 830 Page 4190 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Electronically Controlled Transmission And A/T Indicator-Connectors Page 2718 Key to Diagrams Power Window Page 3339 Page 2551 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4151 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2987 Ground Points 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. How to Read Power Source Page 4204 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Specifications Axle Nut: Specifications Backing Plate Mounting Nuts (4) 68 Nm (50 ft.lb) Page 1306 Intake Manifold: Specifications Throttle Body Fasteners 20 Nm (14 ft.lb) Page 1923 Vapor Pressure Sensor: Description and Operation 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. Page 4010 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 29) Page 2142 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4432 Ground Points 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. How to Read Power Source Page 1724 Page 4364 Braking Sensor/Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 957 Finding A Short Circuit 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: 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) Voltage Check Page 4867 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Relay Blocks Relay Blocks Page 4692 Wheel Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 631 Service and Repair Parking Pawl: Service and Repair ON-VEHICLE REPAIR 1 REMOVE VALVE BODY 2. REMOVE PARKING LOCK PAWL BRACKET 3. REMOVE SPRING FROM PARKING LOCK PAWL SHAFT 4. REMOVE PARKING LOCK PAWL AND SHAFT 5. INSTALL PARKING LOCK PAWL AND SHAFT 6. INSTALL SPRING TO PARKING LOCK PAWL SHAFT Page 3678 Diagram Information and Instructions ABS Main Relay: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Diagrams Timing Chain: Diagrams Page 4876 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1798 CHART 15 Specifications Water Pump: Specifications Water Pump Bolts 14 mm head bolt 24.5 Nm (18 ft.lb) 12 mm head bolt 8.9 Nm (78 in.lb) Page 1705 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 3386 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3919 Axle Shaft: Service and Repair REMOVAL Page 1773 Engine Bank Identification Page 1668 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4560 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 14 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4252 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Front Page 602 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3797 Finding A Short Circuit 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: 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) Voltage Check Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness and Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Ground Points Ground Points Page 3679 Service and Repair Crankshaft Main Bearing Seal: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 3255 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2182 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1875 Page 1777 Page 4610 Vacuum Brake Booster: Service and Repair REMOVAL 1. Remove master cylinder. a. Remove the 4 nuts, 3-way and check valve bracket. Torque: 13 Nm (9 ft. lbs.) b. Pull out the master cylinder and gasket 2. Disconnect vacuum hose from brake booster. 3. Remove these parts: - Return spring. - Clip and clevis pin. - Clevis. 4. Remove brake booster. a. Remove the 4 booster installation nuts. Page 3469 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2115 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3746 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 2626 CHART 28 Specifications Brake Caliper: Specifications Bleeder Plug 96 in.lb Caliper To Steering Knuckle 90 ft.lb Page 3121 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3184 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2008 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 3037 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 586 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4644 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4528 Locations Page 2756 Ground Points 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. How to Read Power Source Page 1956 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3230 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 333 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 619 Engine Bank Identification Page 1587 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3261 Page 4683 Page 1071 A/C Clamp Remover for removing special air condition line clamps. Applicable: 1998 and newer Toyota models with the new style A/C clamps. Comparable to Toyota Tool numbers 09870-00015 and 09870-00025. - Made in USA - Fits both Toyota AC Clamps, used on high and low pressure lines. - Applicable to: 1998 and newer Toyota models - Stainless Steel release pins - Identification and Instructions are laser marked on the handle Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 Page 1267 VALVE SHIMS Page 842 Key to Diagrams Power Window Page 2637 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1834 Page 1697 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2790 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3628 Step 1 Page 1941 Finding A Short Circuit 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: 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) Voltage Check Page 2762 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4869 Location Of Splice Points (Fig 38) Page 364 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Specified amount 2RZ-FE ................................................................................................................... .......................................................... 1.35L (1.43 Qt) 3RZ-FE/5VZ-FE 4WD Extra Long Model ........ .............................................................................................................................................................. .......... 2.45L (2.58 Qt) With Locking Differential: Short Model ............................................................ ...................................................................................................................................... 2.65L (2.80 Qt) Extra Long Model .......................................................................................................................... ............................................................... 2.95L (3.18 Qt) Less Locking Differential ............................ .................................................................................................................................................. 2.55L (2.69 Qt) Page 2553 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 832 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 328 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3589 no continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Page 4729 Battery: Technical Service Bulletins Electrical - Battery Maintenance and Testing PRODUCT GENERAL INFORMATION PG001-06 Title: BATTERY MAINTENANCE FOR IN-STOCK VEHICLES & PRE-DELIVERY Models: All Models & Model Years January 26, 2006 TSB REVISION NOTICE: ^ November 28, 2006: "Required SSTs" have been updated (SST P/N 00002-MCGR8 has been added). "Recommended Equipment" has been removed (superseded by SST P/N 00002-MCGR8). Screen prints and text have been updated in the "Battery Inspection Procedure". "Battery Service Procedure" has been renamed "Battery Inspection Results". Two sections have been added for SST P/N 00002-MCGR8: "Battery Charging Procedure" and "Battery Charging Results". PLEASE READ ENTIRE TSB. Previous versions of this TSB should be discarded. TSB UPDATE NOTICE: The information contained in this TSB supersedes TSB No. PG017-02. TSB No. PGO17-02 is now obsolete and should be discarded. Introduction A battery in a stored vehicle is subject to conditions that can reduce its performance and life. These conditions include storage period, temperature, parasitic drain, and battery load. Because of these factors, battery inspection and maintenance are required in order to ensure proper operation and optimal battery life. As a matter of policy, Toyota does not provide battery warranty coverage for discharged and/or failed batteries due to lack of maintenance. It is the dealer's responsibility to maintain the specified State of Charge (SOC) of the vehicle's battery while in stock and assure proper State of Charge (SOC) at delivery. To eliminate customer service concerns due to an undercharged battery during the first few weeks of ownership, all dealers should check battery State of Charge (SOC) and recharge, if necessary, within 48 hours of delivery to customers. Applicable Vehicles ^ All models and model years. Warranty Information Page 2109 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 2095 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3945 Companion Flange: Specifications Less Differential Lock SERVICE SPECIFICATIONS Vertical Runout: Maximum ............................................................................................................................................. .................................... 0.09 mm (0.0035 inch) Horizontal Runout: Maximum ............................................................................................................................................. .................................... 0.09 mm (0.0035 inch) TORQUE SPECIFICATIONS Companion Flange To Drive Pinion: Standard .............................................................................................................................................. ........................................ 147 Nm (109 ft. lbs.) Maximum .................................................................. .................................................................................................................. 451 Nm (333 ft. lbs.) Locations Page 1921 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2567 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2428 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1913 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 257 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4784 b. Using a screwdriver, hold the spring back and disconnect the brush from the brush holder. Disconnect the 4 brushes and remove the brush holder. 5. REMOVE ARMATURE FROM FIELD FRAME REPLACEMENT 1. REMOVE MAGNETIC SWITCH END COVER Remove the 3 bolts, lead clamp, end cover, gasket and plunger. 2. INSPECT CONTACT PLATE FOR WEAR 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. 3. REMOVE TERMINAL KIT PARTS a. Using SST, loosen the terminal nuts. SST 09810-38140 b. Terminal C: Remove the terminal nut, wave washer, terminal insulator (outside), O-ring, terminal bolt, contact plate and terminal insulator (inside). c. Terminal 30: Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate, terminal insulator (inside) and insulation paper. Page 46 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 4125 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4121 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 845 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2883 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4343 Key to Diagrams Power Window Page 1658 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2094 Ground Points 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. How to Read Power Source Page 238 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1607 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 3113 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Capacity Specifications Refrigerant: Capacity Specifications Refrigerant R134A 20.8 oz Specifications Brake Fluid: Specifications Required Brake Fluid SAE DOT3 Page 3362 Locations-R/B No.2-Engine Compartment Left (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND: Approx 13 Ohms P 1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 4-GROUND: Approx. 12 Volts with ignition SW ON position S 5 STOP LIGHT SW 1-2: Closed with Brake Pedal Depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open Page 647 CHART 20 Page 1279 Drive Belt: Service and Repair REMOVAL 1. REMOVE PS PUMP DRIVE BELT 2. REMOVE ENGINE UNDER COVER 3. LOOSEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 4. REMOVE COMPRESSOR DRIVE BELT Loosen drive belt tension by adjusting bolt and remove the drive belt. INSTALLATION 1. TIGHTEN IDLE PULLEY LOCK NUT TEMPORALLY Torque: 2.5 N.m (25 kgf.cm, 22 in.lbf) 2. INSTALL DRIVE BELT 3. USING ADJUSTING BOLT, ADJUST DRIVE BELT TENSION Drive belt tension New belt: 160 ± 25 lbf Used belt: 100 ± 25 lbf 4. TIGHTEN IDLE PULLEY LOCK NUT Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) 5. INSTALL PS PUMP DRIVE BELT 6. INSTALL ENGINE UNDER COVER Page 4826 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3048 Page 693 Key to Diagrams Power Window Page 2029 Finding A Short Circuit 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: 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) Voltage Check Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less Page 383 Ground Points 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. How to Read Power Source Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2574 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1772 Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4100 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2352 A/F and 02 Sensor Identification Connecting Rod Connecting Rod: Specifications Connecting Rod DIMENSIONS Clearance: Oil: Standard ................................................................................................................................................ 0.030 0.055 mm (0.0012 - 0.0022 inch) U/S 0.25 ................................................................................................................................................ 0.031 0.071 mm (0.0012 - 0.0026 inch) Maximum ........................................................................................ ................................................................................... 0.10 mm (0.0039 inch) Piston Pin Oil: Standard ................................................................................................................................................ 0.005 0.011 mm (0.0002 - 0.0004 inch) Maximum ........................................................................................ ................................................................................. 0.015 mm (0.0006 inch) Thrust: STD ....................................................................................................................................................... 0.160 - 0.312 mm (0.0063 - 0.0123 inch) Maximum ............................................................................ ............................................................................................... 0.35 mm (0.0138 inch) Diameter: Big End Inside: Standard: Mark 4 ......................................................................................................................................... 56.000 - 56.006 mm (2.2047 - 2.2050 inch) Mark 5 ......................................................................................................................................... 56.006 56.012 mm (2.2050 - 2.2052 inch) Mark 6 ......................................................................................................................................... 56.012 56.018 mm (2.2052 - 2.2054 inch) Undersize: 0.25 .............................................................................................................................................. 56.000 - 56.018 mm (2.2047- 2.2054 inch) Bolt Outside: Standard .................................................................................................................................................... 7.80 - 7.90 mm (0.3071 - 0.3110 inch) Minimum ......................................................................................... .................................................................................. 7.60 mm (0.2992 inch) Bushing Inside: Standard (New) ...................................................................................................................................24.008 - 24.017 mm (0.9452 - 0.9455 inch) Piston Pin: Standard (New) ................................................................................................................................. 24.000 - 24.009 mm (0.9449 - 0.9452 inch) Rod: Out-Of-Alignment: Maximum Per 100 mm (3.94 inch) .................................................................................................................................... 0.05 mm (0.0020 inch) Twist: Maximum Per 100 mm (3.94 inch) .................................................................................................................................... 0.15 mm (0.0059 inch) Thickness: Bearing Center Wall: Standard: Mark 4 ............................................................................................................................................. 1.482 - 1.485 mm (0.0583 - 0.0585 inch) Mark 5 ............................................................................................................................................. 1.485 1.488 mm (0.0585 - 0.0586 inch) Mark 6 ............................................................................................................................................. 1.488 1.491 mm (0.0586 - 0.0587 inch) Undersize: 0.25 ................................................................................................................................................. 1.601 - 1.607 mm (0.0630 - 0.0633 inch) TIGHTENING SPECIFICATIONS Rod Cap To Connecting Rod 1st Pass ............................................................................................................................................... ............................................ 45 Nm (33 ft. lbs.) 2nd Pass ................................................................... .................................................................................................................... Turn Additional 90° Page 3508 Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2547 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4273 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 414 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3497 Finding A Short Circuit 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: 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) Voltage Check Page 1357 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Service and Repair Clutch Hydraulic System: Service and Repair If any service is performed on the clutch system or air is suspected in the clutch lines, bleed the system. 1. Fill clutch reservoir with suitable brake fluid. Do not allow fluid to come in contact with painted surfaces. 2. Check reservoir frequently, add fluid as required. 3. Connect vinyl tube to bleeder plug, then insert other tube end in half full container of brake fluid. 4. Slowly pump clutch pedal several times. 5. While depressing, pedal, loosen bleeder plug until fluid runs out, then close bleeder plug. 6. Repeat procedure until air bubbles are evident in the fluid. Do not reuse the fluid that was bled. Page 159 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3650 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3185 Ground Points 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. How to Read Power Source Locations Page 2978 Fuel Line Inspection 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. Page 3238 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3428 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 715 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4093 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3169 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3189 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4807 Auxiliary Power Outlet: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1391 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 1021 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS (a) Remove the air cleaner cap and MAF meter assembly. (b) Remove the intake air connector. (c) Disconnect the high-tension cords from the spark plugs. NOTICE: Pulling on or bending the cords may damage the conductor inside. (d) 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. (e) Using an ohmmeter, measure the resistance. Maximum resistance: 25 k ohms per cord Page 4325 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3861 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 386 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3018 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 3464 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 7 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2685 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4238 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 259 Finding A Short Circuit 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: 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) Voltage Check Page 456 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Specifications Wheel Speed Sensor: Specifications Speed Sensor Installation Bolt 71 in.lb Front Speed Sensor Harness To: Upper Arm 71 in.lb Side Rail 108 in.lb Rear Speed Sensor Harness To: Axle Housing 108 in.lb Fuel Tank 108 in.lb Side Rail 108 in.lb Page 4095 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2722 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4625 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4695 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4522 Loosen/Tighten Bleeder Plug 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) 11 Nm (8 ft. lbs.) 5. Repeat procedure for each wheel. 6. Bleed Load Sensing Proportioning & By-Pass Valve (LSP & BV). LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Page 1598 Engine Control Module: Testing and Inspection Related Diagnostic Procedures 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 (Making: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 2979 Fuel Tank: Service and Repair FUEL TANK AND LINES Toyota does not provide written instructions for Fuel Tank removal. Refer to the illustration above and observe the following precautions and procedures. WARNING: Before attempting to remove the fuel tank, observe the following precautions: Be sure to have a Class B, dry chemical fire extinguisher close to the work area. - Wear safety glasses. - Siphon or pump fuel into an explosion-proof container to prevent the possibility of explosion or fire. - Always use new gaskets when replacing the fuel tank or component parts. - When re-installing, be sure to include the rubber protectors on the upper surfaces of the fuel tank and tank band. - Apply the proper torque to all parts tightened. PROCEDURES Page 4353 Page 4158 Overdrive Indicator Lamp: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 4645 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Testing and Inspection Control Module HVAC: Testing and Inspection INSPECT AMPLIFIER CIRCUIT a. Remove the glove compartment door. b. Disconnect the amplifier connector and inspect the connector on wire harness side, as shown in the chart. Test conditions: ^ Turn ignition switch to ON ^ Blower speed switch HI If the circuit is not as specified, inspect the circuits connected to other parts. c. Connect the connector to amplifier and inspect wire harness side connector from the back side, as shown in the chart. Test conditions ^ Running engine at idle speed ^ Blower speed switch at "HI" position ^ A/C switch ON ^ Temperature control lever at "COOL" position ^ Set on manifold gauge set 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. Page 4304 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3001 Idle Speed/Throttle Actuator - Electronic: Description and Operation 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. Page 1808 CHART 24 Diagrams Page 2009 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 292 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Remove speed sensor. a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. - The sensor is installed flat against the axle end when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. Specifications Brake Rotor/Disc: Specifications Thickness: Standard 0.866 in Minimum 0.787 in Runout: Maximum 0.0028 in Page 876 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2355 Page 4407 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2280 Engine Control Module: Testing and Inspection Related Diagnostic Procedures 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 (Making: EFI) and supplying power to terminal +B of the ECM. WIRING DIAGRAM Step 1 Page 2503 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1660 Page 390 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4814 Power Outlet-Connectors Page 2698 Key to Diagrams Power Window Page 3982 Overdrive Indicator Lamp: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2625 Page 1919 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3998 Step 3 Page 1695 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Locations Tail Lamp Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1998 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Specifications Parking Brake Lever: Specifications Lever Travel At: 196 N (44.1 lbs.) .................................................................................................................................. ........................................................... 12-18 clicks Page 2269 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3739 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 1498 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: N-cap, 108 kPa Page 3996 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 3142 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2998 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1935 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2504 Key to Diagrams Power Window Page 854 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 3044 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1871 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2638 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill Capacity (manual transmission) 8.5 qt (US) Capacity (automatic transmission) 8.2 qt (US) Page 678 Finding A Short Circuit 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: 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) Voltage Check Bleeding the Brake System Brake Bleeding: Service and Repair Bleeding the Brake System BLEEDING HINT: If any work is done on the brake system or if air is suspected in the brake lines, bleed the system of air. NOTICE: Do not let brake fluid remain on a painted surface. Wash it off immediately. Fill Brake Reservoir 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 brake lines from the master cylinder. b. Slowly depress the brake pedal and hold it. c. Block off the outlet plug with your finger, and release the brake pedal. d. Repeat b) and c) 3 or 4 times. 3. Connect vinyl tube to brake caliper or wheel cylinder bleeder plug. Insert other end of the tube in a half-full container of brake fluid. HINT: Begin air bleeding from the wheel cylinder with the longest hydraulic line. Page 787 Finding A Short Circuit 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: 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) Voltage Check Page 2481 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 640 CHART 10 Page 504 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2380 Page 3232 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 650 CHART 22 Page 3315 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4617 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness and Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Ground Points Ground Points Page 156 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4608 Page 4493 E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the 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 flow chart. 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. NOTE: ^ Clean excess grease. from brake pad and caliper. ^ 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: Page 3821 Page 4180 Locations-R/B No.2-Engine Compartment Left (Fig 19) Service Hints E 2 ELECTRONICALLY CONTROLLED TRANSMISSION SOLENOID 1, 2, 3-GROUND: Approx 13 Ohms P 1 A/T INDICATOR LIGHT SW [PARK/NEUTRAL POSITION SW] 4-GROUND: Approx. 12 Volts with ignition SW ON position S 5 STOP LIGHT SW 1-2: Closed with Brake Pedal Depressed E 5-A, E 6-B, E 7-C, E 8-D ENGINE CONTROL MODULE S1-E1: 9-14 Volts S2, SL-E1: 0-1.5 Volts BK-E1: 7.5-14 Volts with Brake Pedal Depressed 0-1.5 Volts with Brake Pedal Released THW-E2: 0.2-1.0 Volts with Coolant Temp. 80° C (176° F) OIL-E2: 4-5 Volts with fluid Temp. 20° C (68° F) VTA-E2: 0.3-0.8 Volts with Throttle Valve fully closed 3.2-4.9 Volts with Throttle Valve fully open Page 3500 Shift Solenoid: Description and Operation DESCRIPTION Shift Solenoid 1-2 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.). 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. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunctioning, hydraulic control cannot be performed electronically and must be done manually. Shift Solenoid Valve SL 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. Page 1999 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3279 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4244 Step 1 Step 2 Page 3425 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 3521 Clutch: Diagrams Page 4022 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4011 Position Of Parts In Instrument Panel (1 Of 2) (Fig 30) Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3612 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 3330 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 3522 Page 3036 Ground Points 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. How to Read Power Source Page 793 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 2676 Key to Diagrams Power Window Locations Blower Motor Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4066 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Locations Antenna Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 447 Locations-J/B No.3 Behind The Instrument Panel Left (Fig 22) Relay Blocks Relay Blocks Page 2486 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 680 Page 3415 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4445 Wheel Speed Sensor: Description and Operation CIRCUIT DESCRIPTION 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. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 4230 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3593 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 922 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3556 Overdrive Indicator Lamp: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2026 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4064 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4352 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 810 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3731 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2295 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Compression Check: Specifications Compression Pressure 1230 kPa (178 psi) or more Minimum Pressure 880 kPa (127 psi) Difference Between Each Cylinder 98 kPa (14 psi) or less ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2786 Ground Points 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. How to Read Power Source Page 4422 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2655 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1711 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Specifications Valve Clearance: Specifications Valve Clearance (Cold) Intake 0.15-0.25 mm (0.006-0.010 in) Exhaust 0.25-0.35 mm (0.010-0.014 mm) Page 4281 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4557 Hydraulic Control Assembly - Antilock Brakes: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3380 Step 2 Step 3 INSPECTION PROCEDURE Page 4816 Power Outlet Page 2470 Page 272 Page 708 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Testing and Inspection Page 155 Ground Points 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. How to Read Power Source Page 2738 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2294 Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4106 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 1706 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 4295 ABS Light: Description and Operation 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 to make the ABS warning light blink and output the DTC. Page 2055 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 3866 Differential Axle Housing: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Differential; Service and Repair. Page 4128 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2127 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3582 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 24) Parts Location Parts Location Specifications Engine Oil Pressure: Specifications Oil Pressure at Idle 29 kPa (4.3 psi) or more Oil Pressure at 3000 rpm 245-490 kPa (36-71 psi) Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3172 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1145 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3227 Ground Points 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. How to Read Power Source Page 3604 Shift Indicator: Testing and Inspection CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. WIRING DIAGRAM Step 1 Page 3808 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Service and Repair Front Crankshaft Seal: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Oil Pump; Service and Repair. With Differential Lock Carrier Side Gears: Application and ID With Differential Lock Side Gear Thrust Washer Thickness: .............................................................................................................................................................. ............................................. 0.9 mm (0.035 inch) ............................................................................... ............................................................................................................................ 1.0 mm (0.039 inch) .............................................................................................................................................................. ............................................. 1.1 mm (0.043 inch) ............................................................................... ............................................................................................................................ 1.2 mm (0.047 inch) .............................................................................................................................................................. ............................................. 1.3 mm (0.051 inch) Page 2155 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Removal and Installation Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal and Installation REMOVAL 1. Remove brake line cover. Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1732 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4755 1. REMOVE DRIVE BELT a. Loosen the lock bolt, pivot bolt, nut and adjusting bolt b. Remove the drive belt. 2. REMOVE GENERATOR a. Disconnect the generator connector. b. Remove the nut, and disconnect the generator wire. Torque: 9.8 N.m (100 kgf.cm, 7.2 ft.lbf) c. Disconnect the wire harness with the clip. d. Remove the lock bolt, pivot bolt, nut and generator. Torque: Pivot bolt: 59 N.m (600 kgf.cm, 43 ft.lbf) Lock bolt: 29 N.m (300 kgf.cm, 21 ft.lbf) INSTALLATION Installation is in the reverse order of removal. Page 118 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2628 CHART 30 Page 4587 Page 617 Applicable Vehicles Electrical - SRS And HV Wiring Repairs Wiring Harness: Technical Service Bulletins Electrical - SRS And HV Wiring Repairs TITLE: SRS & HV WIRING REPAIRS SECTION: ELECTRICAL BULLETIN # 156 MODELS: ALL TOYOTA LEXUS and SCION MODELS DATE: AUGUST 2007 There are no approved repairs to Supplemental Restraint System (SRS) or High Voltage (HV) wiring or connectors. SRS system wiring and connectors are color coded yellow and HV wiring is orange however vehicle-specific wiring diagrams are the best source for identifying wiring in these circuits. Wiring diagrams are available through the Technical Information System (TIS) www.techinfo.toyota.com. If SRS or HV wiring or connectors are suspected of damage they should be inspected thoroughly. Damaged wiring and/or connectors require replacement of the affected harness. Follow all precautions and procedures outlined in model-specific repair manuals for replacing SRS wiring or components. Only Certified Hybrid Service Technicians are qualified to replace HV system wiring and components. Page 3717 Step 1 Step 2 Page 1809 CHART 25 Page 2120 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3078 Reference (c) Using an ohmmeter, measure the resistance between each terminal. Page 2408 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4700 Wheel Speed Sensor: Description and Operation CIRCUIT DESCRIPTION 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. Fail safe function: If trouble occurs in the speed sensor circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 4130 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 658 Page 940 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Diagram Information and Instructions Diagnostic Connector - ABS: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1004 Idle Speed: Testing and Inspection 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. Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the Idle Air Control (IAC) valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 539 Key to Diagrams Power Window Page 2360 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 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. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," 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. Example: Page 2514 Page 2990 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 994 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 1715 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove speed sensor. a. Disconnect the speed sensor connector. b. Remove the 2 (4WD) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (71 inch lbs.) Side rail: 13 Nm (9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. Page 2165 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3086 Ground Points 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. How to Read Power Source Page 4332 Finding A Short Circuit 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: 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) Voltage Check Page 1872 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2799 Vapor Pressure Sensor: Description and Operation 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. Page 4686 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2290 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4400 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 112 Key to Diagrams Power Window Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Specifications Piston: Specifications 2RZ-FE Engine Piston Diameter Std. 94.923-94.933 mm O/S 0.50 95.423-95.433 mm Piston Oil Clearance Std. 0.057-0.080 mm 3RZ-FE Engine Piston Diameter Std. 94.933-94.943 mm O/S 0.50 95.433-95.443 mm Piston Oil Clearance Std. 0.047-0.070 mm Locations Starter Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1605 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2331 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 40 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 Step 1 Page 758 Key to Diagrams Power Window Page 603 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2647 Oxygen Sensor: Testing and Inspection INSPECTION INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the heated oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohms at 20°C (68°F) Bank 1 Sensor 2: 11 - 16 ohms at 20°C (68°F) if resistance is not as specified, replace the heated oxygen sensor. (c) Reconnect the heated oxygen sensor connector. Page 377 Step 4 INSPECTION PROCEDURE Page 360 Clutch Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4651 Finding A Short Circuit 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: 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) Voltage Check Page 1532 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. c. Check the valve lift. Valve lift: 8 mm (0.31 inch) 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. INSTALLATION 1. PLACE THERMOSTAT IN WATER INLET HOUSING a. Install a new gasket to the thermostat. b. Align the jiggle valve of the thermostat with the protrusion of the water inlet housing, 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. CONNECT WATER INLET WITH LOWER RADIATOR HOSE Install the water inlet with the 2 nuts. HINT: Facing the top mark (protrusion) upward. Torque: 20 Nm (200 kgf.cm, 15 ft. lbs.) 3. FILL WITH ENGINE COOLANT 4. START ENGINE AND CHECK FOR LEAKS Page 114 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4254 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1341 21. REMOVE BALANCE SHAFT DRIVE GEAR, SHAFT, NO.2 TIMING CHAIN AND NO.2 CRANKSHAFT TIMING SPROCKET a. Remove the bolt from the balance shaft drive gear. b. Remove the balance shaft drive gear with the shaft. c. Remove the No.2 timing chain with the No.2 crankshaft timing sprocket. 22. REMOVE NO.4 VIBRATION DAMPER Remove the 2 bolts and No.4 damper. INSPECTION 1. INSPECT TIMING CHAINS, TIMING GEARS AND TIMING SPROCKETS a. Measure the length of 16 links with the chain fully stretched. Maximum chain elongation: No.1 Timing chain: 147.5 mm (5.807 inch) 3RZ-FE: No.2 Timing chain: 123.6 mm (4.866 inch) If the elongation is greater than maximum, replace the chain. HINT: Make the same measurements pulling at 3 or more places selected at random. b. Wrap the chain around the timing gear and timing sprocket. Page 1963 Finding A Short Circuit 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: 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) Voltage Check Page 3842 ^ If there are 2 alignment pins present the transmissionltransaxle assembly may be installed following the applicable Repair Manual procedure. NOTE: A missing alignment pin may result in failure of the transmissionltransaxle assembly. 2. Install the missing alignment pin(s). ^ Refer to the applicable Repair Manual procedure for location of the cylinder block rear side alignment pins. NOTE In the Repair Manual, the alignment pin is referred to as a "straight pin." Page 1292 w/ Oil filter change: 5.4 liters (5.7 U S qts., 4.8 Imp. qts.) w/o Oil filter change: 4.7 liters (5.0 US qts., 4.1 Imp. qts.) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL Page 3892 Pinion Gear: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Differential; Service and Repair. Page 1539 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE COOLANT 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe from the fan shroud. 4. DISCONNECT UPPER RADIATOR HOSE FROM RADIATOR 5. REMOVE OIL DIPSTICK GUIDE a. Remove the bolt, dipstick guide and engine wire bracket. b. Remove the O-ring from the dipstick guide. HINT: At the time of installation, please refer to the following items. Use a new O-ring. Page 4091 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2471 Page 1915 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1108 Engine Oil: Service and Repair 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. REPLACE OIL FILTER a. Using Special Service Tool (SST), remove the oil filter. (SST) 09228-07501 b. Check and clean the oil filter installation surface. c. Apply clean engine oil to the gasket of a new oil filter. d. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. e. Using SST, tighten it an additional 3/4 turn. SST 09228-07501 3. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. Torque: 37 Nm (375 kgf.cm, 27 ft. lbs.) b. Fill with fresh engine oil. Oil capacity 2WD: Dry fill: 6.2 liters (6.6 US qts., 5.5 Imp. qts.) Drain and refill w/ Oil filter change: 5.5 liters (5.8 US qts., 4.8 Imp. qts.) w/o Oil filter change: 4.8 liters (5.0 US qts., 4.2 Imp. qts.) 4WD: Dry fill: 5.8 liters (6.1 US qts., 5.1 Imp. qts.) Drain and refill Page 1518 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 254 Braking Sensor/Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4049 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 918 Ground Points 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. How to Read Power Source Page 1446 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1486 RADIATOR AND RELATED COMPONENTS Page 1080 Coolant: Fluid Type Specifications Using coolant which includes more than 50% ethylene-glycol (but not more than 70%) is recommended. Page 4736 10. Select the appropriate model and press the NEXT soft key. 11. Select OEM battery type and press the NEXT soft key. 12. Choose the correct battery (model number and CCA) and press the NEXT soft key. The battery will be tested before charging will occur. The progress bar fills in across the screen while testing. Service and Repair Piston Pin: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Diagram Information and Instructions Igniter: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3976 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4758 a. Remove the 4 nuts. b. Using SST, remove the rectifier end frame. SST 09286-46011 6. REMOVE ROTOR FROM DRIVE END FRAME REASSEMBLY 1. PLACE DRIVE END FRAME ON PULLEY 2. INSTALL ROTOR TO DRIVE END FRAME 3. INSTALL RECTIFIER END FRAME a. Using a 29 mm socket wrench and press, slowly press in the rectifier end frame. b. Install the 4 nuts. Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf) Page 1672 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 412 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 157 Key to Diagrams Power Window Page 4813 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2474 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 1826 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2572 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2135 Ground Points 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. How to Read Power Source Page 4899 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1631 Igniter: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 231 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4619 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2523 Ground Points 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. How to Read Power Source Page 4498 Brake Pad: Service and Repair REPLACEMENT 1. Remove front wheel. 2. Inspect pad lining thickness. Check the pad thickness and replace pads if not within specification. Minimum thickness: 1.0 mm (0.039 inch) 3. Remove these parts: - Clip. - 2 pins. - Anti-rattle spring. - 2 pads. - 4 anti-squeal shims. Page 1866 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3770 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1932 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4183 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3832 b. Install the oil strainer case with the 5 bolts. Torque: 10 Nm (100 kgf-cm, 7 ft. lbs.) c. Install a new gasket to the oil strainer case. d. Install the oil strainer with the 11 bolts. Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.) 16. INSTALL OIL PAN a. A340E: Install the 4 magnets in the indications of the oil pan. b. A340F: Install the 6 magnets in the indications of the oil pan. Page 1492 Radiator: Service and Repair On-Vehicle Cleaning 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) Page 2570 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4416 2. Disconnect connector. Pull out the release bar, and disconnect the connector. 3. Disconnect brake lines. Using Special Service Tool (SST) 09023-00100 or equivalent, disconnect the 5 brake lines from the ABS actuator. Torque: 15 Nm (11 ft. lbs.) 4. Remove ABS actuator assembly Remove the bolt, 2 nuts and ABS actuator assembly. Torque: 19 Nm (14 ft. lbs.) 5. Remove ABS actuator. Using a T25 torx wrench, remove the 3 bolts and ABS actuator from actuator bracket. Torque: 9 Nm (7 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. Locations Page 2489 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2624 CHART 27 Page 649 CHART 21 Page 1454 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 354 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2536 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Brakes - Pad Clicking Noise Brake Pad: Customer Interest Brakes - Pad Clicking Noise BRAKES BR004-00 October 20, 2000 Title: BRAKE PAD CLICKING NOISE Models: '90- '00 All Models 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 ^ 1990 - 2000 model year Toyota vehicles, all models. Parts Information Warranty Information Application Procedure 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. Page 1109 w/ Oil filter change: 5.4 liters (5.7 U S qts., 4.8 Imp. qts.) w/o Oil filter change: 4.7 liters (5.0 US qts., 4.1 Imp. qts.) Reinstall the oil filler cap. 4. START ENGINE AND CHECK FOR LEAKS 5. RECHECK ENGINE OIL LEVEL Diagram Information and Instructions Data Link Connector: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3275 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2375 CHART 14 Diagram Information and Instructions Overdrive Indicator Lamp: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2607 CHART 12 CHART 13 Page 716 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1540 6. w/PS: REMOVE DRIVE BELT FOR PS PUMP Loosen the lock bolt and adjusting bolt, and remove the drive belt. 7. REMOVE FAN SHROUDS a. Remove the 2 clips and No.2 fan shroud. b. Remove the 4 bolts and No.1 fan shroud. 8. w/ A/C: REMOVE DRIVE BELT FOR A/C COMPRESSOR Loosen the idler pulley nut and adjusting bolt, and remove the drive belt. 9. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY a. Stretch the belt and loosen the water pump pulley nuts. b. Loosen the lock, pivot and adjusting bolts of the generator, and remove the drive belt. c. Remove the 4 water pump pulley nuts. Torque: 21 Nm (210 kgf.cm, 16 ft. lbs.) d. Pull out the fan together with the fluid coupling and water pump pulley. 10. REMOVE WATER PUMP Remove the 10 bolts, water pump and gasket. Torque: 14 mm head bolt: 24.5 Nm (250 kgf.cm, 18 ft. lbs.) 12 mm head bolt: 8.9 Nm (90 kgf.cm, 78 inch lbs.) HINT: At the time of installation, please refer to the following items. Use a new gasket. Diagram Information and Instructions Auxiliary Power Outlet: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness and Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Ground Points Ground Points Page 2410 Finding A Short Circuit 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: 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) Voltage Check Page 850 Finding A Short Circuit 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: 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) Voltage Check Page 1751 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2369 CHART 5 CHART 6 Page 648 Page 3153 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS (a) Remove the air cleaner cap and MAF meter assembly. (b) Remove the intake air connector. (c) Disconnect the high-tension cords from the spark plugs. NOTICE: Pulling on or bending the cords may damage the conductor inside. (d) 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. (e) Using an ohmmeter, measure the resistance. Maximum resistance: 25 k ohms per cord Page 1630 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4122 Ground Points 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. How to Read Power Source Page 4575 2WD 78 mm (3.07 inch) 4WD 120 mm (4.72 inch) Adjustment range: 2WD 72 - 84 mm (2.83 - 3.31 inch) 4WD 114 - 126 mm (4.49 - 4.96 inch) HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: 2WD 55 kPa (8.0 psi) 4WD 52 kPa (7.5 psi) b. If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure-Lower body High pressure- Raise body c. Torque the nuts. Torque: 13 Nm (9 ft. lbs.) d. Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. 5. If necessary, check valve body. a. Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 inch). Even at this time, the piston should not make contact with or move the load sensing spring. b. In this position, check the rear brake pressure. 2WD: Front brake pressure 1,960 kPa (285 psi) Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 3333 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4246 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 2511 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2289 Ground Points 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. How to Read Power Source Page 3714 Step 1 Page 2860 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check that the battery positive voltage is above 12 volts. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the union bolt and 2 gaskets and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. (d) Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (e) Wipe off any splattered gasoline. (f) Connect the TOYOTA hand-held tester to the DLC3. (g) Turn the ignition switch ON and 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. (k) Reconnect the negative (-) terminal cable to the battery. (l) Turn the ignition switch ON. (m)Measure the fuel pressure. Fuel pressure: Page 336 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3045 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3491 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1396 Compression Check: Testing and Inspection 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 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Page 4152 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 207 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 675 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1149 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2461 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4191 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission (Part 1 Of 3) Denso Made System Brake Switch (Cruise Control): Testing and Inspection Denso Made System Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake pedal is on depressed, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. 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 is cut mechanically by the stop light switch, turning the cruise control off. WIRING DIAGRAM Step 1 Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 230 Ground Points 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. How to Read Power Source Page 1449 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1033 Compression Check: Testing and Inspection 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 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Page 2324 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1940 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2086 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 4756 Generator: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. REMOVE REAR END COVER a. Remove the nut and terminal insulator. b. Remove the 3 nuts, and end cover. 2. REMOVE BRUSH HOLDER AND VOLTAGE REGULATOR Remove the 5 screws, bush holder and voltage regulator 3. REMOVE RECTIFIER HOLDER Remove the bolt, 4 screws and rectifier holder. 4. REMOVE PULLEY Page 3008 - Transmission in neutral position (b) Using SST, connect terminals TE1 and E1 of the DLC1. SST 09843-18020 (c) After engine speed are kept at 1,000 - 1,500 rpm for 5 seconds, check that they return to idle speed. If the engine speed operation is not as specified, check the IAC valve, wiring and ECM. (d) Remove the SST SST 09843-18020 Page 3077 Throttle Body: Testing and Inspection Component Inspection INSPECTION 1. CLEAN THROTTLE BODY (a) 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. INSPECT THROTTLE VALVE (a) Apply vacuum to the throttle opener. (b) Check that there is no clearance between the throttle stop screw and throttle lever when the closed throttle position. 3. INSPECT THROTTLE POSITION SENSOR (a) Apply vacuum to the throttle opener (b) Insert a thickness gauge between the throttle stop screw and stop lever. Ohmmeter Connection Page 541 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2505 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2661 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4473 4. Remove these parts: - Clip. - 2 pins. - Anti-rattle spring. - 2 pads. - 4 anti-squeal shims. INSTALLATION Installation is in the reverse order of removal. After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. Page 4803 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 29) Page 564 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 742 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1825 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4773 2.0 kW type: 35 mm (1.38 in.) Minimum diameter: 1.4 kW type: 29 mm (1.14 in.) 2.0 kW type: 34 mm (1.34 in.) If the diameter is less than the minimum, replace the armature. 6. INSPECT UNDERCUT DEPTH Check that the undercut depth is clean and free of foreign materials. Smooth out the edge. Standard undercut depth: 1.4 kW type: 0.6 mm (0.024 in.) 2.0 kW type: 0.7 mm (0.028 in.) Minimum undercut depth: 0.2 mm (0.008 in.) If the undercut depth is less than the minimum, correct it with a hacksaw blade. 7. INSPECT 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. 8. INSPECT 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. Page 2988 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3440 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Component Inspection Evaporator Temperature Sensor / Switch: Testing and Inspection Component Inspection INSPECT THERMISTOR RESISTANCE a. Place the thermistor in cold water, and while changing the temperature of the water, measure resistance at the connector and at the same time, measure temperature of the water with a thermometer. b. Compare the 2 readings on the chart. If resistance value is not as specified, replace the thermistor. Page 4428 Page 4812 Finding A Short Circuit 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: 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) Voltage Check Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid A340E Drain & Refill ........................................................................................................................................ .................................................. up to 1.6L (1.7 Qt) Page 2696 Ground Points 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. How to Read Power Source ABS/TCS - Zero Point Calibration Information Alignment: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2796 Finding A Short Circuit 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: 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) Voltage Check Page 1758 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2884 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2588 Ford Made System Cruise Control Module: Testing and Inspection Ford Made System 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 Step 1 Page 2363 Page 1651 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2882 Key to Diagrams Power Window Page 4344 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3499 Shift Solenoid: Electrical Diagrams Capacity Specifications Fluid - A/T: Capacity Specifications A/T Fluid A340E Drain & Refill ........................................................................................................................................ .................................................. up to 1.6L (1.7 Qt) Page 3563 Overdrive Indicator Lamp: Electrical Diagrams Page 2554 Finding A Short Circuit 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: 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) Voltage Check Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Remove front wheel. 2. Disconnect flexible hose. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. 3. Remove caliper. Remove the 2 mounting bolts and caliper. Torque: 123 Nm (90 ft. lbs.) Page 2515 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Brakes - Pad Clicking Noise Brake Pad: All Technical Service Bulletins Brakes - Pad Clicking Noise BRAKES BR004-00 October 20, 2000 Title: BRAKE PAD CLICKING NOISE Models: '90- '00 All Models 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 ^ 1990 - 2000 model year Toyota vehicles, all models. Parts Information Warranty Information Application Procedure 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. Page 3995 Step 2 Step 3 INSPECTION PROCEDURE Page 968 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Diagram Information and Instructions Hydraulic Control Assembly - Antilock Brakes: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Service Specifications Valve Body: Specifications Service Specifications VALVE BODY SPRING SPECIFICATIONS UPPER VALVE BODY LOWER VALVE BODY Page 3891 Pinion Gear: Specifications Less Differential Lock Drive Pinion Preload At Starting: New Bearing ........................................................................................................................................ ........................... 1.1-1.7 Nm (10.0-15.2 inch lbs.) Reused Bearing ................................................... ................................................................................................................ 0.6-0.9 Nm (5.7-8.3 inch lbs.) Drive Pinion To Ring Gear: Backlash .............................................................................................................................................. ...................... 0.13-0.18 mm (0.0051-0.0071 inch) Page 1876 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 2101 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1965 Page 4326 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3718 Step 3 Page 1897 Vehicle Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 1855 Finding A Short Circuit 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: 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) Voltage Check Page 240 Finding A Short Circuit 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: 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) Voltage Check Page 3436 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Locations Page 2605 CHART 10 Page 4499 NOTICE: The anti-rattle spring 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. 4. Check disc thickness and runout. a. Measure disc thickness. Using a micrometer, measure the disc thickness. Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) If the disc is scored or worn, or if its thickness is less than minimum, repair or replace the disc. b. Measure disc runout. 1) Tighten the disc with the 3 hub nuts. 2) Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front bearing play is within specification. 5. Install new pads. NOTICE: When replacing worn pads, the anti-squeal shims must be replaced together with the pads. a. Draw out a small amount of brake fluid from the reservoir. b. Press in the pistons with a monkey wrench handle or equivalent. HINT: Tape the monkey wrench handle before use. - Always change the pad on one wheel at a time as there is a possibility of the opposite piston flying out. - 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 anti-squeal shims to new pads. Exhaust System - Sulfur Smell Fuel: Technical Service Bulletins Exhaust System - Sulfur Smell ENGINE EG003-03 February 24, 2003 Title: SULFUR ODOR FROM EXHAUST Models: All Models Introduction 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. Applicable Vehicles ^ All Models. Repair Procedure 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: ^ 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 Page 3550 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Specifications Harmonic Balancer - Crankshaft Pulley: Specifications Crankshaft Pulley Bolt 260 Nm (193 ft.lb) No.2 & No.3 Crankshaft Pulley Bolts (4) 25 Nm (18 ft.lb) Page 2276 Chart 2 Of 2 Page 2926 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 115 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1117 Power Steering Fluid: Testing and Inspection INSPECTION 1. CHECK FLUID LEVEL a. Keep the vehicle level. b. With the engine stopped, check the fluid level in the oil reservoir. If necessary, add fluid. Fluid: ATF DEXRON II or III HINT: Check that the fluid level is within the HOT LEVEL range on the reservoir cap dipstick. 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: 8O°C (176°F) e. Check for foaming or emulsification. If there is foaming or emulsification, bleed power steering system. f. 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 inch) If a problem is found, bleed power steering system. i. Check the fluid level. 2. CHECK STEERING FLUID PRESSURE a. 5VZ-FE Engine: Loosen the 3 bolts and air cleaner assembly. b. Disconnect the pressure feed tube from the PS vane pump. c. Connect SST, as shown below. SST 09640-10010 (09641-01010, 09641-01030, 09641-01060) Page 4791 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1810 Page 3438 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4787 6. CLEAN CONTACT SURFACES OF CONTACT PLATE AND PLUNGER Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag. 7. REINSTALL MAGNETIC SWITCH END COVER Install the plunger, new gasket, end cover and lead clamp with the 3 bolts. Torque: 1.4 kW type: 2.5 N.m (26 kgf.cm, 23 in.lbf) 2.0 kW type: 3.6 N.m (37 kgf.cm, 32 in.lbf) REASSEMBLY Reassembly is in the reverse order of disassembly. Page 2084 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 2394 CHART 29 Page 2049 Idle Speed: Testing and Inspection 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. Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the Idle Air Control (IAC) valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 4085 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 2167 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3348 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 703 Page 2939 (a) Install a new grommet to the injector. (b) Apply a light coat of gasoline to a new O-ring and install it to the injector. (c) While turning the injector left and right, install it to the delivery pipe. Install the 4 injectors. (d) Position the injector connector upward. 2. INSTALL INJECTORS AND DELIVERY PIPE (a) Place the 4 new insulators and in position on the spacers. (b) Place the 4 injectors together with the delivery pipe in position on the cylinder head. (c) Temporarily install the 2 bolts holding the delivery pipe to the cylinder head. (d) 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. (e) Position the injector connector upward. (f) Tighten the 2 bolts holding the delivery pipe to the cylinder head. Torque: 21 N.m (210 kgf.cm, 15 ft.lbf) (g) Connect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (h) Connect the fuel return hose to the fuel pressure regulator. Page 2403 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 356 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2267 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3146 Page 2759 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4570 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Disconnect connector. 2. Remove ECU a. Using a E5 torx wrench, remove the 4 screws. Torque: 1.8 Nm (16 inch lbs.) 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. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3616 Overdrive Indicator Lamp: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3276 Key to Diagrams Power Window Page 519 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3293 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 4368 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3305 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Testing and Inspection Door Switch: Testing and Inspection INSPECT DOOR COURTESY SWITCH CONTINUITY a. Check that continuity exists between terminal and the switch body in the ON position (switch pin released : opened door). b. Check that no continuity exists between terminal and the switch body in the OFF position (switch pin pushed in : closed door). If operation is not as specified, replace the switch Page 2441 Chart 2 Of 2 Page 1725 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 1155 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 950 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3759 Ground Points 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. How to Read Power Source Page 877 Page 1392 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS (a)Disconnect the high-tension cords from the spark plugs. (b) Using a 16 mm plug wrench, remove the spark plug. (c) Using a spark plug cleaner or wire brush, clean the spark plug. (d) Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA (e) Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) (f) Using a 16 mm plug wrench, install the spark plug. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (g) Connect the high-tension cords to the spark plugs. Page 189 Starter Relay: Testing and Inspection 1. REMOVE STARTER RELAY LOCATION: The relay is located in the junction block on the driver's side. 2. INSPECT STARTER RELAY CONTINUITY a. 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. 3. INSPECT STARTER RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 4. REINSTALL STARTER RELAY Page 974 breaker operates. If operation is as specified, replace the master switch. Page 2526 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Locations Overdrive Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2891 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4733 The battery is now being tested. The progress bar fills in across the screen while testing. 12. Read or print the battery test results (press the PRINT soft key to print). Battery Inspection Results Once the test completes, proceed with one of the 5 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: "GOOD BATTERY" Return the battery to service. 2. Battery Condition: "GOOD-RECHARGE" Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and return it to service. 3. Battery Condition: "CHARGE & RETEST" Fully charge the battery using the GR8 Battery Diagnostic Station (P/N 00002-MCGR8) and retest. NOTE: Failure to fully charge the battery before retesting may cause false readings. 4. Battery Condition: "REPLACE BATTERY" Replace the battery. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out-of-vehicle test before replacing it. 5. Battery Condition: "BAD CELL-REPLACE" Replace the battery. The decision indicates a bad cell within the battery. CAUTION: ^ If "FROZEN BATTERY" is displayed as the test result, allow the battery to reach a temperature of 40°F (4°C) before retesting. ^ NEVER CHARGE A FROZEN BATTERY GASES MAY FORM, CRACKING THE CASE AND CAUSING BATTERY ACID TO LEAK. Page 3411 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2719 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink O/D Cancel Signal Circuit Overdrive Indicator Lamp: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 3397 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1251 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 2082 Valve Clearance: Testing and Inspection INSPECTION HINT: Inspect and adjust the valve clearance when the engine is cold. 1. REMOVE INTAKE AIR CONNECTOR 2. REMOVE PCV HOSES 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. DISCONNECT ENGINE WIRE a. Disconnect these connectors: - w/ A/C: A/C compressor connector - Oil pressure sensor connector - Engine coolant temperature sender gauge connector - Ignition Coil connector b. Disconnect the 4 engine wire clamps and engine wire. 5. REMOVE CYLINDER HEAD COVER Remove the 10 bolts, seal washers, cylinder head cover and gasket. 6. SET NO.1 CYLINDER TO TDC/COMPRESSION a. Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover. b. Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above. 7. INSPECT VALVE CLEARANCE Page 494 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 315 Finding A Short Circuit 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: 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) Voltage Check Page 2930 Finding A Short Circuit 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: 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) Voltage Check Page 2843 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4370 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1648 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4810 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4179 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Relay Blocks Relay Blocks Page 2170 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 3229 Key to Diagrams Power Window Page 522 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4760 Install the rectifier holder with the bolt and 4 screws. Torque: Screw: 1.96 N.m (20 kgf.cm, 17.4 in.lbf) Torque: Bolt: 3.9 N.m (40 kgf.cm, 34.7 in.lbf) 6. INSTALL VOLTAGE REGULATOR AND BRUSH HOLDER a. Install the brush holder cover to the brush holder. NOTE: Be careful of the holder installation direction. b. Place the voltage regulator together with the brush holder horizontally on the rectifier end frame. c. Install the 5 screws until there is a clearance of approx. 1 mm (0.04 in.) between the brush holder and connector. Torque: 1.96 N.m (20 kgf.cm, 17.4 in.lbf) 7. INSTALL REAR END COVER a. Install the end cover with the 3 nuts. Torque: 4.5 N.m (46 kgf.cm, 40 in.lbf) b. Install the terminal insulator with the nut. Torque: 4.1 N.m (42 kgf.cm, 36 in.lbf) 8. CHECK THAT ROTOR ROTATES SMOOTHLY Page 4775 If the installed load is not within specification, replace the brush springs. 12. INSPECT 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. 13. INSPECT GEAR TEETH Check the gear teeth on the pinion gear, idle gear and clutch assembly for wear or damage. If damaged, replace the gear or clutch assembly. If damaged, also check the fly wheel ring gear for wear or damage. 14. INSPECT CLUTCH PINION GEAR Hold the starter clutch and rotate the pinion gear clockwise, and check that it turns freely. Try to rotate the pinion gear counterclockwise and check that it locks. It necessary, replace the clutch assembly. 15. INSPECT FRONT BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 16. IF NECESSARY, REPLACE FRONT BEARING a. Using SST, remove the bearing. SST 09286-46011 Page 2575 Mechanical Specifications Power Steering Fluid: Mechanical Specifications Oil Level Rise: Maximum ............................................................................................................................................. ....................................... Below 5 mm (0.20 inch) Page 4663 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3444 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4750 b. Reverse the polarity of the tester probes and repeat step (a). c. Check that one shows continuity and the other shows no continuity. If continuity is not as specified, replace the rectifier holder. 10. INSPECT FRONT BEARING Check that the bearing is not rough or worn. 11. IF NECESSARY, REPLACE FRONT BEARING a. Remove the 4 screws, bearing retainer and bearing. b. Using SST and press, press out the bearing. SST 09950-60010 (09951-00260, 09952-06010) c. Using SST and a press, press in a new bearing. SST 09950-60010 (09951-00500) d. Install the bearing retainer with the 4 screws. Torque: 2.6 N.m (26.5 kgf.cm, 23 in.lbf) 12. INSPECT REAR BEARING Check that the bearing is not rough or worn. 13. IF NECESSARY, REPLACE REAR BEARING Page 2392 Page 1716 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Front Page 2326 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3833 c. Remove any packing material and be careful not to drop oil on the contacting surfaces of the transmission case and oil pan. d. Apply FIPG to the oil pan. FIPG: Part No. 08826 - 00090, THREE BOND 1281 or equivalent e. Install the oil pan with the 19 bolts. Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) 17. INSTALL DRAIN PLUG Torque: 20 Nm (205 kgf-cm, 15 ft. lbs.) 18. FILL AND CHECK ATF Page 4905 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Testing and Inspection Idle Speed/Throttle Actuator - Mechanical: Testing and Inspection THROTTLE OPENER INSPECTION (a) Allow the engine to warm up to normal operating temperature. (b) Check the idle speed. Idle speed: 650 - 750 rpm (c) Disconnect the vacuum hose from the throttle opener and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 1,200 - 1,500 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. (h) Disconnect TOYOTA hand-held tester or OBD II scan tool. Page 766 Finding A Short Circuit 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: 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) Voltage Check Page 3935 Wheel Bearing: Service Precautions Use only a grease that is recommended for wheel bearing applications. Use of the improper grease can cause bearing damage. Page 2134 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3733 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2208 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1987 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Page 4696 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4904 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Locations Page 4264 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2389 CHART 26 Page 671 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Diagram Information and Instructions Wheel Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2919 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4448 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Remove speed sensor. a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. - The sensor is installed flat against the axle end when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. Page 4494 ^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.) ^ 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. 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 4306 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Locations Page 2597 Page 3956 HINT: When replacing the propeller shaft, install new parts facing, as shown in the illustration. 1. 3-joint type: INSTALL CENTER SUPPORT BEARING ON INTERMEDIATE SHAFT Install the center support bearing and spacer. HINT: Install the center support bearing with the cutout toward the rear. 2. 3-joint type: INSTALL FLANGE ON INTERMEDIATE SHAFT a. Coat the splines of the intermediate shaft with MP grease. b. Place the flange on the shaft and align the matchmarks. HINT: If replacing either the center flange or intermediate shaft, reassemble them so that the front flange yoke of the intermediate shaft and the rear flange yoke of the propeller shaft are facing in the same direction. Page 2074 Spark Plug: Testing and Inspection INSPECT SPARK PLUGS (a)Disconnect the high-tension cords from the spark plugs. (b) Using a 16 mm plug wrench, remove the spark plug. (c) Using a spark plug cleaner or wire brush, clean the spark plug. (d) Check the spark plug for electrode wear, threads damage and insulator damage. If abnormal, replace the plugs. Recommended spark plugs: ND: K16R-U NGK: BKR5EYA (e) Carefully bend the outer electrode to obtain the correct electrode gap. Correct electrode gap: 0.8 mm (0.031 in.) (f) Using a 16 mm plug wrench, install the spark plug. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (g) Connect the high-tension cords to the spark plugs. Page 4835 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3410 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1774 A/F and 02 Sensor Identification Electrical Specifications Fuel Injector: Electrical Specifications Resistance Resistance Resistance Between Terminals 12 to 16 ohms at 68 deg F Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3137 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3369 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1655 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1291 Engine Oil: Service and Repair 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. REPLACE OIL FILTER a. Using Special Service Tool (SST), remove the oil filter. (SST) 09228-07501 b. Check and clean the oil filter installation surface. c. Apply clean engine oil to the gasket of a new oil filter. d. Lightly screw the oil filter into place, and tighten it until the gasket contacts the seat. e. Using SST, tighten it an additional 3/4 turn. SST 09228-07501 3. REFILL WITH ENGINE OIL a. Clean and install the oil drain plug with a new gasket. Torque: 37 Nm (375 kgf.cm, 27 ft. lbs.) b. Fill with fresh engine oil. Oil capacity 2WD: Dry fill: 6.2 liters (6.6 US qts., 5.5 Imp. qts.) Drain and refill w/ Oil filter change: 5.5 liters (5.8 US qts., 4.8 Imp. qts.) w/o Oil filter change: 4.8 liters (5.0 US qts., 4.2 Imp. qts.) 4WD: Dry fill: 5.8 liters (6.1 US qts., 5.1 Imp. qts.) Drain and refill Diagrams Page 3649 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1790 CHART 2 CHART 3 CHART 4 Locations Fuse: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1784 Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4359 Ground Points 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. How to Read Power Source Page 2458 Ground Points 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. How to Read Power Source Page 2967 Fuel Supply Line: Service and Repair PRECAUTION 1. BEFORE WORKING ON FUEL SYSTEM, DISCONNECT NEGATIVE (-) TERMINAL CABLE FROM BATTERY HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal cable is removed from the battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL SYSTEM (a) When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe these procedures: (1) Put a container under the connection. (2) Slowly loosen the connection. (3) Disconnect the connection. (4) Plug the connection with a rubber plug. (b) When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedures: (1) (Union Bolt Type) Always use a new gasket. (2) (Union Bolt Type) Tighten the union bolt by hand. (3) (Union Bolt Type) Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (4) (Flare Nut Type) Apply a light coat of engine oil to the flare and tighten the flare nut by hand. (5) (Flare Nut Type) Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Page 3791 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 557 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Testing and Inspection Power Steering Pressure Switch: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF. 2. CHECK IDLE-UP. a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 3598 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission (Part 1 Of 3) Page 2451 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 2382 CHART 22 Diagram Information and Instructions Braking Sensor/Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1994 Ground Points 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. How to Read Power Source Page 3216 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2758 Key to Diagrams Power Window Page 4877 Power Outlet-Connectors Page 3063 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 188 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1836 Oxygen Sensor: Testing and Inspection INSPECTION INSPECT HEATER RESISTANCE OF HEATED OXYGEN SENSORS (a) Disconnect the heated oxygen sensor connector. (b) Using an ohmmeter, measure the resistance between terminals +B and HT. Resistance: Bank 1 Sensor 1: 11 - 16 ohms at 20°C (68°F) Bank 1 Sensor 2: 11 - 16 ohms at 20°C (68°F) if resistance is not as specified, replace the heated oxygen sensor. (c) Reconnect the heated oxygen sensor connector. Page 2845 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3448 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 3923 a. Using SST and a press, remove the bearing. SST 09223-56010, 09950-60010 (09951-00560) b. Using SST and a press, install a new bearing. SST 09515-30010, 09950-60020 (09951-00890) 7. INSTALL NEW OUTER OIL SEAL Using SST and a hammer, install a new oil seal. SST 09950-60010 (09951-00610), 09950-70010 (09951-07150) 8. REPLACE BEARING CASE a. Remove the oil seal (outer side) and bearing. b. Install 4 nuts to the serration bolts. c. Using a hammer, remove the serration bolts and bearing case. d. Position the backing plate on a new bearing case and using 2 socket wrenches, install the serration bolts. e. Install a new bearing and oil seal (outer side). Page 2601 CHART 2 CHART 3 CHART 4 Page 1082 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The coolant level should be between the "L" and "F" lines. If low, check for leaks and add coolant up to the "F" line. 2. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. WARNING: 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 scales 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. Page 543 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagrams Page 2740 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4323 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2366 O2S Application Table O2S Failure Threshold Charts Page 492 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4327 Acceleration/Deceleration Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4181 VCC-E2: 4.5-5.5 Volts OD1-E1: 4.5-5.5 Volts OD2-E1: 9-14 Volts O/D main SW turned ON 0 Volts O/D main SW turned OFF SP1-E1: Pulse Generation with vehicle moving 2-E1: 10-14 Volts with Shift Lever at 2 position 0-2 Volts with Shift Lever at except 2 position L-E1: 10-14 Volts with Shift Lever at L position 0-2 Volts with Shift Lever at except L position +B-E1: 9-14 Volts BATT-E1: 9-14 Volts Splice Points Splice Points Location Of Splice Points (Fig 38) System Outline Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 Page 644 CHART 15 Page 1807 Page 698 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3435 Ground Points 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. How to Read Power Source Page 4821 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3041 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4127 Shift Solenoid: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4439 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4176 Position Of Parts In Engine Compartment (Part 1 Of 2) (Fig 28) Page 361 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4147 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3494 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1743 Finding A Short Circuit 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: 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) Voltage Check Page 1794 CHART 10 Page 3765 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2584 Engine Bank Identification Page 3042 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3737 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3920 HINT: Pre-runner is the model described below. RZN191L-TRPDKAB, RZN196L-CRPDKAB, VZN195L-CRPDKAB 1. REMOVE REAR WHEEL AND BRAKE DRUM Torque: 110 Nm (1,150 kgf-cm, 83 ft. lbs.) 2. CHECK BEARING BACKLASH AND AXLE SHAFT DEVIATION a. Using a dial indicator, check the backlash in the bearing shaft direction. Maximum: 0.7 mm (0.028 inch) If the backlash exceeds the maximum, replace the bearing. b. Using a dial indicator, check the deviation at the surface of the axle shaft outside the hub bolt. Maximum: 0.1 mm (0.0039 inch) If the deviation exceeds the maximum, replace the axle shaft. 3. w/ ABS: REMOVE ABS SPEED SENSOR FROM REAR AXLE HOUSING Remove the bolt and ABS speed sensor. Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.) 4. REMOVE REAR BRAKE ASSEMBLY Page 4646 Acceleration/Deceleration Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3006 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. Page 1945 Air Flow Meter/Sensor: Description and Operation 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. Page 3449 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 3456 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 1635 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 195 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3317 Shift Solenoid: Description and Operation DESCRIPTION Shift Solenoid 1-2 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.). 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. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunctioning, hydraulic control cannot be performed electronically and must be done manually. Shift Solenoid Valve SL 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. Page 939 Step 3 Page 2179 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2465 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1444 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Fuse: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Chart 1 Of 2 Page 1629 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3212 Igniter: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1713 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4294 Page 2950 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 885 Air Bag Deactivation Switch: Testing and Inspection INSPECTION Connector Terminal Identification Reference Chart 1. INSPECT PASSENGER AIRBAG CUTOFF SWITCH CONTINUITY HINT: Release airbag activation prevention mechanism of the passenger airbag cutoff switch connector on the airbag sensor assembly side. If continuity is not as specified, replace the switch. 2. INSPECT PASSENGER AIR BAG CUT OFF INDICATOR OPERATION a. Check that continuity exists between 6 and 7. b. Connect the positive (+) lead from the battery to terminal 1 and negative (-) lead to terminal 4. c. Check that the indicator light lights up. If the operation is not as specified, replace the indicator. Page 527 Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1779 A/F and 02 Sensor Identification Page 3988 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1782 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 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. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," 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. Example: Page 3089 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 63 Backup Lamp Relay: Testing and Inspection INSPECT BACK-UP LIGHT RELAY CONTINUITY If continuity is not as specified, replace the relay. Page 256 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1338 11. REMOVE OIL PAN a. Remove the 16 bolts and 2 nuts. b. Insert the blade of Special Service Tool (SST) between the cylinder block and oil pan, cut off applied sealer and remove the oil pan. (SST) 09032-00100 NOTICE: Be careful not to damage the oil pan flanges of the oil pan and cylinder block. 12. REMOVE OIL STRAINER Remove the bolt, 2 nuts, oil strainer and gasket. 13. REMOVE CRANKSHAFT PULLEY a. w/ A/C: Remove the 4 bolts, No.2 and No.3 crankshaft pulleys. b. Using SST, remove the pulley bolt. SST 09213-54015, 09330-00021 c. Remove the crankshaft pulley. HINT: If necessary, remove the pulley with SST and crankshaft pulley bolt. SST 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09954-05020) 14. REMOVE TIMING CHAIN COVER Page 4811 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3309 Shift Solenoid: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2361 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. 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. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. 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, Os [seconds], 10.2s, 0 and 255). Page 3599 Electronically Controlled Transmission (Part 2 Of 3) Page 2721 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 761 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4177 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 29) Page 4231 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3760 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2203 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1887 Key to Diagrams Power Window Page 4167 O/D OFF indicator light remains ON Page 4187 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4500 HINT: Apply disc brake grease to both sides of inner anti-squeal shims. d. Install the 2 pads. NOTICE: Do not allow oil or grease to get on the rubbing face. 6. Install anti-rattle spring and 2 pins. 7. Install clip. Page 4782 Starter Motor: Service and Repair Disassembly and Reassembly DISASSEMBLY HINT: Use high-temperature grease to lubricate the bearings, gears, return spring and steel ball when assembling the starter. 1. REMOVE FIELD FRAME AND ARMATURE a. Remove the nut and disconnect the lead wire from the magnetic switch terminal. Torque: 5.9 N.m (60 kgf.cm, 52 in.lbf) b. Remove the 2 through bolts. Torque: 1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf) 2.0 kW type: 9.3 N.m (93 kgf.cm, 82 in.lbf) c. Pull out the field frame with the armature from the magnetic switch assembly. NOTE: Align the protrusion of the field frame with the cutout of the magnetic switch. d. Remove the O-ring. HINT: ^ Use a new O-ring. ^ Align the protrusion of the field frame with the cutout of the magnetic switch. 2. REMOVE STARTER HOUSING, CLUTCH ASSEMBLY AND GEAR Page 2907 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 960 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3806 Transmission Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3789 Key to Diagrams Power Window Page 4097 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3059 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4622 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2251 Finding A Short Circuit 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: 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) Voltage Check Page 4879 Power Outlet Page 3983 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2266 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1939 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1280 Drive Belt: Tools and Equipment Toyota Serpentine Belt Wrench AST tool# TOY 1914 The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008. - Lightweight and Slim design - Equipped with 14mm and 19mm, 12 point securing attachments - Works on most Toyota applications (except Hybrids) Contact AST for pricing. Page 4258 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Service Specifications Fluid Pump: Specifications Service Specifications Oil Pump Body Clearance Standard .............................................................................................................................................. .................. 0.07 - 0.15 mm (0.0028 - 0.0059 inch) Maximum ............................................................. .............................................................................................................................. 0.3 mm (0.012 inch) Tip Clearance Standard .............................................................................................................................................. .................. 0.11 - 0.14 mm (0.0043 - 0.0055 inch) Maximum ............................................................. .............................................................................................................................. 0.3 mm (0.012 inch) Side Clearance Standard .............................................................................................................................................. .................. 0.02 - 0.05 mm (0.0008 - 0.0020 inch) Maximum ............................................................. .............................................................................................................................. 0.1 mm (0.004 inch) Pump Body Bushing Inside Diameter, Maximum ........................................................................................................................... 38.19 mm (1.5035 inch) Stator Shaft Bushing Inside Diameter Front Side Maximum ........................................................................................................................... ........................................ 21.58 mm (0.8496 inch) Rear Side Maximum ............................................ ........................................................................................................................ 27.08 mm (1.0661 inch) Drive Gear and Driven Gear Thickness Mark 1 .................................................................................................................................................. ............................. 9.440 - 9.449 (0.3717 - 0.3720 Mark 2 .................................................................. ............................................................................................................ 9.450 - 9.459 (0.3720 0.3724) Mark 3 .................................................................................................................................... .......................................... 9.460 - 9.470 (0.3724 - 0.3728) Mark 4 .................................................... .......................................................................................................................... 9.471 - 9.480 (0.3720 - 0.3724) Mark 5 .................................................................................................................................. ............................................ 9.481 - 9.490 (0.3729 - 0.3736) Page 4727 least once a month to lubricate the compressor. 1. Turn off A/C and blower switches prior to starting engine. 2. Start and warm up the engine until engine idle drops below 1,000 rpm. 3. Turn on the A/C system (including the rear A/C) using the following settings: A. A/C Switch: On B. Blower Speed: High C. Engine Speed: Below 1,000 RPM 4. Keep A/C on with engine idling for at least one minute (in dual A/C vehicles leave on for two minutes). 5. Turn off A/C system and stop engine. Disk Brake Rotor Surface Rust Removal The brake rotors are made of cast iron so they may show gradual build-up of surface rust during long term storage. At least once every two months drive the vehicle and use the brakes normally stopping from about 30 mph at least 20 times. This regular usage will help prevent severe rust build up and the possibility of unwanted brake vibration concerns due to rust. NOTE ^ If the brake vibration still occurs after the braking cycle, determine the root cause of the brake vibration and repair. ^ Brake rotor resurfacing may be required if the rust was severe and resulted in excessive rotor thickness variation. Page 3605 Step 2 Step 3 INSPECTION PROCEDURE Page 4864 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 24) Parts Location Parts Location Page 2028 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1693 Key to Diagrams Power Window Page 4132 Finding A Short Circuit 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: 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) Voltage Check Page 769 Vapor Pressure Sensor: Description and Operation 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. Page 4080 Step 1 Page 1959 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2844 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1978 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Chart 1 Of 2 Page 355 Ground Points 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. How to Read Power Source Page 1618 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Page 1786 Page 4308 ABS Main Relay: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 925 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2548 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 109 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4820 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1885 Ground Points 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. How to Read Power Source Page 560 Key to Diagrams Power Window Page 416 Finding A Short Circuit 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: 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) Voltage Check Page 727 Page 3984 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2708 Vehicle Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 1409 Water Pump: Diagrams Page 452 Position Of Parts In Body (Fig 32) ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2590 A/F and 02 Sensor Identification Page 3387 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3409 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4148 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1811 CHART 26 Page 3532 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .................................. DEXRON II or DEXRON III Page 3716 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Diagram Information and Instructions Braking Sensor/Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1583 Key to Diagrams Power Window Testing and Inspection EGR Backpressure Transducer: Testing and Inspection 1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR 2. INSPECT EGR VACUUM MODULATOR OPERATION (a) Block ports P and R with your finger. (b) Blow air into port Q and check that the air passes through to the air filter side freely. (c) Start the engine and maintain speed at 3,000 rpm. (d) Repeat the above test. Check that there is a strong resistance to air flow. If operation is not as specified, replace the EGR vacuum modulator. 15. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Page 1888 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4677 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 2596 Page 667 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4460 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Page 4314 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2264 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 872 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 141 Fuel Pump Relay: Testing and Inspection INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY (a) Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION (a) Apply battery positive voltage across terminals STA and E1. (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. (c) Apply battery positive voltage across terminals +B and FC. (d) Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 3206 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 525 Finding A Short Circuit 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: 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) Voltage Check Page 4349 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3243 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 2527 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4631 ABS Main Relay: Description and Operation 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. Fail safe function: If trouble occurs in the ABS relay circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 4150 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3479 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.). 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. Page 449 Splice Points Location Of Splice Points (Fig 38) System Outline Current always flows to TERMINAL 12 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 6 of the integration relay. At the same time, current flows to TERMINAL A-2 of the relay from the GAUGE fuse through the Seat Belt Warning Light. This current activates the integration relay and, for Approx. 4-8 Seconds, current flowing through the warning light flows from TERMINAL A-2 of relay to TERMINAL A-7 to GROUND, causing the warning Light to Light up. At the same time as the warning Light Lights up, a buckle SW ON signal is input to TERMINAL A-3 of the integration relay, the current flowing from TERMINAL 12 of the relay flows to TERMINAL A-7 to GROUND and the Seat Belt Warning Buzzer Sounds for Approx. 4-8 Seconds. However, if the Seat Belt is put ON (Buckle SW OFF) during this period (While The Buzzer Is Sounding), signal input to TERMINAL A-3 of the integration relay Stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A-7 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 front LH door open (Door Courtesy SW ON), when a signal is input to TERMINAL A-10 of the integration relay, the Integration Relay operates, current flows from TERMINAL 6 of the relay to TERMINAL A-7 to GROUND and the Key Reminder Buzzer Sounds. Parts Location Parts Location Page 1947 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 2920 Ground Points 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. How to Read Power Source Page 3850 Carrier Side Gears: Application and ID Less Differential Lock Side Gear Thrust Washer Thickness: .............................................................................................................................................................. ......................................... 1.50 mm (0.0590 inch) ............................................................................... ........................................................................................................................ 1.55 mm (0.0610 inch) .............................................................................................................................................................. ......................................... 1.60 mm (0.0630 inch) ............................................................................... ........................................................................................................................ 1.65 mm (0.0650 inch) .............................................................................................................................................................. ......................................... 1.70 mm (0.0669 inch) ............................................................................... ........................................................................................................................ 1.75 mm (0.0689 inch) .............................................................................................................................................................. ......................................... 1.80 mm (0.0709 inch) ............................................................................... ........................................................................................................................ 1.85 mm (0.0728 inch) .............................................................................................................................................................. ......................................... 1.90 mm (0.0748 inch) Side Bearing Adjusting Washer Thickness: 58 ......................................................................................................................................................... .......................................... 2.58 mm (0.1015 inch) 60 ......................................................................... .......................................................................................................................... 2.60 mm (0.1024 inch) 62 ................................................................................................................................................ ................................................... 2.62 mm (0.1031 inch) 64 ................................................................ ................................................................................................................................... 2.64 mm (0.1039 inch) 66 ................................................................................................................................... ................................................................ 2.66 mm (0.1047 inch) 68 ................................................... ................................................................................................................................................ 2.68 mm (0.1055 inch) 70 ............................................................................................................................ ....................................................................... 2.70 mm (0.1063 inch) 72 ............................................ ....................................................................................................................................................... 2.72 mm (0.1071 inch) 74 .................................................................................................................... ............................................................................... 2.74 mm (0.1079 inch) 76 .................................... .............................................................................................................................................................. . 2.76 mm (0.1087 inch) 78 .................................................................................................................. ................................................................................. 2.78 mm (0.1094 inch) 80 .................................. .............................................................................................................................................................. ... 2.80 mm (0.1102 inch) 82 ................................................................................................................ ................................................................................... 2.82 mm (0.1110 inch) 84 ................................ .............................................................................................................................................................. ..... 2.84 mm (0.1118 inch) 86 .............................................................................................................. ..................................................................................... 2.86 mm (0.1126 inch) 88 .............................. .............................................................................................................................................................. ....... 2.88 mm (0.1134 inch) 90 ............................................................................................................ ....................................................................................... 2.90 mm (0.1142 inch) 92 ............................ .............................................................................................................................................................. ......... 2.92 mm (0.1150 inch) 94 .......................................................................................................... ......................................................................................... 2.94 mm (0.1157 inch) 96 .......................... .............................................................................................................................................................. ........... 2.96 mm (0.1165 inch) 98 ........................................................................................................ ........................................................................................... 2.98 mm (0.1173 inch) 00 ........................ .............................................................................................................................................................. ............. 3.00 mm (0.1181 inch) 02 ...................................................................................................... ............................................................................................. 3.02 mm (0.1189 inch) 04 ...................... .............................................................................................................................................................. ............... 3.04 mm (0.1197 inch) 06 .................................................................................................... ............................................................................................... 3.06 mm (0.1205 inch) 08 .................... .............................................................................................................................................................. ................. 3.08 mm (0.1213 inch) 10 .................................................................................................. ................................................................................................. 3.10 mm (0.1220 inch) 12 .................. .............................................................................................................................................................. ................... 3.12 mm (0.1228 inch) 14 ................................................................................................ ................................................................................................... 3.14 mm (0.1236 inch) 16 ................ .............................................................................................................................................................. ..................... 3.16 mm (0.1244 inch) 18 .............................................................................................. ..................................................................................................... 3.18 mm (0.1252 inch) 20 .............. .............................................................................................................................................................. ....................... 3.20 mm (0.1260 inch) 22 ............................................................................................ ....................................................................................................... 3.22 mm (0.1268 inch) 24 ............ .............................................................................................................................................................. ......................... 3.24 mm (0.1276 inch) 26 .......................................................................................... ......................................................................................................... 3.26 mm (0.1283 inch) 28 .......... .............................................................................................................................................................. ........................... 3.28 mm (0.1291 inch) 30 ........................................................................................ ........................................................................................................... 3.30 mm (0.1299 inch) 32 ........ .............................................................................................................................................................. ............................. 3.32 mm (0.1307 inch) 34 ...................................................................................... ............................................................................................................. 3.34 mm (0.1315 inch) 36 ...... .............................................................................................................................................................. ............................... 3.36 mm (0.1323 inch) 38 .................................................................................... ............................................................................................................... 3.38 mm (0.1331 inch) 40 .... .............................................................................................................................................................. ................................. 3.40 mm (0.1339 inch) 42 .................................................................................. ................................................................................................................. 3.42 mm (0.1346 inch) 44 .. .............................................................................................................................................................. ................................... 3.44 mm (0.1354 inch) 46 ................................................................................ ................................................................................................................... 3.46 mm (0.1362 inch) 48 .............................................................................................................................................................. ..................................... 3.48 mm (0.1370 inch) Page 4552 Ground Points 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. How to Read Power Source Diagram Information and Instructions Vapor Pressure Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Specifications Engine Oil Pressure: Specifications Oil Pressure at Idle 29 kPa (4.3 psi) or more Oil Pressure at 3000 rpm 245-490 kPa (36-71 psi) Page 2709 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 4283 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3112 Ground Points 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. How to Read Power Source Page 4640 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2395 CHART 30 Page 4006 Junction Block and Wire Harness Connector Locations-J/B No.1 Lower Finish Panel (Fig 20) Page 1519 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3989 Overdrive Indicator Lamp: Electrical Diagrams Diagrams Page 2674 Ground Points 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. How to Read Power Source Page 760 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2274 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 620 A/F and 02 Sensor Identification Page 95 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Testing and Inspection Positive Crankcase Ventilation: Testing and Inspection INSPECTION 1. REMOVE PCV VALVE 2. INSTALL CLEAN HOSE TO PCV VALVE 3. INSPECT PCV VALVE OPERATION (a) 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. (b) 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. 4. REMOVE CLEAN HOSE FROM PCV VALVE 5. REINSTALL PCV VALVE 6. VISUALLY INSPECT HOSES, CONNECTIONS AND GASKETS Check for cracks, leaks or damage. Page 1884 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Service and Repair Oil Filter: Service and Repair For information regarding the service and repair of this component, please refer to Oil; Service and Repair. Page 2587 Applicable Vehicles Page 2725 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 530 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Page 166 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2271 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 212 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 3093 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 691 Ground Points 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. How to Read Power Source Page 3862 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4286 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2180 Key to Diagrams Power Window Page 2385 Page 450 Position Of Parts In Instrument Panel (1 Of 2) (Fig 30) Page 3343 Step 1 Page 3800 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 2666 Finding A Short Circuit 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: 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) Voltage Check Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4721 Starter Relay: Testing and Inspection 1. REMOVE STARTER RELAY LOCATION: The relay is located in the junction block on the driver's side. 2. INSPECT STARTER RELAY CONTINUITY a. 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. 3. INSPECT STARTER RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 4. REINSTALL STARTER RELAY Page 251 Key to Diagrams Power Window Page 2789 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 206 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1815 CHART 28 Locations Fuse: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 130 Engine Control Module: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO. 2 PANEL 3. REMOVE ECM (a) Disconnect the 4 ECM connectors. (b) Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 307 Key to Diagrams Power Window Page 1783 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. 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. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. 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, Os [seconds], 10.2s, 0 and 255). Testing and Inspection Heater Control Valve: Testing and Inspection 1. WARM UP ENGINE 2. DISCONNECT WATER VALVE CONTROL CABLE 3. INSPECT WATER VALVE OPERATION a. Check that warm air blown out the vent when the water valve lever is moved to "WARM" position. b. Check that cool air blown out when the water valve is moved to the "COOL" position. If operation is not as specified, replace the water valve. 4. CONNECT WATER VALVE CONTROL CABLE After connection, adjust the control cable. Page 2620 CHART 25 Page 801 Key to Diagrams Power Window Page 1694 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 375 Clutch Switch: Testing and Inspection Ford Made System 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 Step 1 Page 432 Evaporator Temperature Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 2. REMOVE THERMISTOR a. Disconnect the connector clamp. b. Pull out the thermistor from evaporator. INSTALLATION Installation is in the reverse order of removal. Page 4708 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 1634 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3648 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2870 Idle Speed: Testing and Inspection 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. Sequential Multiport Fuel Injection (SFI) system wiring connectors fully plugged g. Ignition timing check correctly h. Transmission in neutral position 2. CONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL 3. INSPECT IDLE SPEED a. Race the engine speed at 2,500 rpm for approximately 90 seconds. b. Check the idle speed. Idle speed: 650 - 750 rpm If the idle speed is not as specified, check the Idle Air Control (IAC) valve, intake air leakage and SFI system. 4. DISCONNECT TOYOTA HAND-HELD TESTER OR OBD II SCAN TOOL Page 601 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3133 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4665 Braking Sensor/Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1589 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2546 Key to Diagrams Power Window Page 1063 TOY 730 - 73mm Toyota Oil Filter Wrench M 0219 - 74mm Oil Filter Wrench Page 2329 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2013 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 3314 Finding A Short Circuit 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: 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) Voltage Check Page 894 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2102 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2538 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 1422 Coolant: Testing and Inspection INSPECTION 1. CHECK ENGINE COOLANT LEVEL AT RADIATOR RESERVOIR The coolant level should be between the "L" and "F" lines. If low, check for leaks and add coolant up to the "F" line. 2. CHECK ENGINE COOLANT QUALITY a. Remove the radiator cap. WARNING: 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 scales 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. Page 878 Knock Sensor: Description and Operation 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. Page 4289 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 636 CHART 2 CHART 3 CHART 4 Page 363 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4037 Fluid - M/T: Fluid Type Specifications M/T Fluid Grade ................................................................................................................................................... ..................................................... API GL-4 or GL-5 Viscosity .............................................................................................................................................. .............................................................. SAE 75W-90 Page 3830 c. A340E: Install the 17 bolts. Torque: 10 Nm (1100 kgf -cm, 7 ft. lbs.) Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) d. A340F: Install the 16 bolts. Torque: 10 Nm (1100 kgf -cm, 7 ft. lbs.) Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) 12. CONNECT CONNECTOR TO EACH SHIFT SOLENOID VALVE 13. INSTALL OIL PIPE a. A340E: Using a plastic hammer, install the 2 pipes into position. NOTICE: Be careful not to bend or damage the pipes. Make sure that the oil pipes or magnet do not Interfere with the oil pan. Page 2936 (h) Connect SST (union and hose) to the injector and hold the injector and union with SST (clamp). SST 09268-41046 (i) Put the injector into a graduated cylinder. HINT: Install a suitable vinyl hose onto the injector to prevent gasoline from splashing out. (j) Connect the TOYOTA hand-held tester to the DLC3. (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: 69 - 88 cu.cm (4.2 - 5.4 Cu in.) per 15 seconds Difference between each injector: 5 cu.cm (0.3 cu in.) or less If the injection volume is not as specified, replace the injector 2. INSPECT LEAKAGE (a) 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 3 minutes (b) Turn the ignition switch to LOCK. (c) Disconnect the negative (-) terminal cable from the battery. (d) Remove the SST and TOYOTA hand-held tester. SST 09268-41045 (e) Reinstall the fuel pressure regulator and fuel inlet pipe. Page 717 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Electrical Specifications Generator: Electrical Specifications Testing - Voltage/Amperage Testing - Voltage/Amperage Regulating Voltage 13.7 to 14.7 V at 77 deg F 13.2 to 14.0 V at 239 deg F Rated - Voltage/Amperage Rated - Voltage/Amperage Rated Output 70 A at 12 V Rotor Coil Resistance 2.1 to 2.5 ohms Page 1812 Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3124 Page 4070 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2493 Page 4067 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2096 Key to Diagrams Power Window Page 1981 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 959 Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 562 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2245 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2162 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1432 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. Capacity Specifications Coolant: Capacity Specifications Drain and Refill Drain and Refill Capacity (manual transmission) 8.5 qt (US) Capacity (automatic transmission) 8.2 qt (US) Page 3263 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 3028 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 823 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Locations Power Distribution Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2482 Key to Diagrams Power Window Page 3734 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3581 Locations-J/B No.3 Behind The Instrument Panel Left (Fig 22) Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 3555 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2952 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 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 - Injectors (n) Remove the TOYOTA hand-held tester. (o) Start the engine. (p) Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kgf/sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Stop the engine. (r) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (s) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (t) Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 2143 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 177 Air Bag Control Module: Service and Repair 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 THESE PARTS: a. front console box b. lower center cover 2. REMOVE AIRBAG SENSOR ASSEMBLY a. Disconnect the connector. NOTICE: Remove the connector with the sensor assembly installed. b. Using a torx wrench remove the 3 screws and the airbag sensor assembly. Torx wrench: T40 (Part No. 09042-00020 or locally manufactured tool) INSTALLATION NOTICE: ^ Never use SRS parts from another vehicle. When replacing parts, replace with new parts. ^ Never reus the airbag sensor assembly Involved In a collision hen the airbag has deployed. ^ Never repair a sensor in order to reuse it. 1. INSTALL Al BAG SENSOR ASSEMBLY a. Using a torx wrench, install the 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 connector. NOTICE: ^ Installation of the connector is done after the sensor assembly as been installed. ^ Make sure the sensor assembly is installed to the specified torque. ^ If the sensor assembly has been dropped, or there are cracks, defects or other defects in the case, bracket or connector, replace the sensor assembly with a new one. ^ When instaling the airbag 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. Page 4792 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2467 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3346 Step 1 Step 2 Page 4623 ABS Main Relay: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2198 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Page 2125 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3332 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Specifications Axle Nut: Specifications Backing Plate Mounting Nuts (4) 68 Nm (50 ft.lb) Drivetrain - Drive/Axle Shaft Replacement Precautions Drive/Propeller Shaft: Technical Service Bulletins Drivetrain - Drive/Axle Shaft Replacement Precautions TRANSMISSION & CLUTCH TC003-07 Title: DRIVESHAFT ASSEMBLY REPLACEMENT Models: '90 - '07 Toyota Introduction The purpose of this bulletin is to provide information regarding anti-corrosion grease that is present on replacement driveshaft assemblies. It is important to remove this grease prior to installing the hub nut to prevent overtightening. This also applies when reusing an old driveshaft that may have come into contact with oil or foreign matter. Applicable Vehicles ^ 1990 - 2007 model year Toyota vehicles. Required Tools & Material Repair Procedure Clean the threaded area of the driveshaft with Toyota Brake Cleaner (or equivalent) to remove the anti-corrosion grease, oil, or foreign matter before installing the driveshaft into the vehicle. NOTE: A new axle hub nut may be required when installing the driveshaft. Check the Repair Manual procedure for more information. Warranty Information Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2494 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 1524 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Specifications Firing Order: Specifications Firing order: 1-3-4-2 Page 2767 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4153 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 599 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3366 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagram Information and Instructions Hydraulic Control Assembly - Antilock Brakes: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1617 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4580 b. Position the valve body so that the valve piston lightly contacts the load sensing spring. c. Tighten the valve body mounting nuts. Torque: 13 Nm (9 ft. lbs.) 6. Bleed brake line. 7. Check and adjust LSP & BV fluid pressure. Page 3603 Shift Indicator: Description and Operation Electronically Controlled Transmission and A/T Indicator Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Page 1683 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Testing and Inspection EGR Valve: Testing and Inspection REMOVE EGR VALVE (a) Disconnect these hoses: (1) Vacuum hose (2) EGR hose (3) Water bypass hose (from IAC valve) (4) Water bypass hose (from water bypass pipe) (b) Remove the 2 nuts, EGR valve and gasket. Torque: 19 N.m (195 kgf.cm, 14 ft.lbf) (c) INSPECT EGR VALVE Check for sticking and heavy carbon deposits. If a problem is found, replace the EGR valve. Page 121 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Testing and Inspection EGR Backpressure Transducer: Testing and Inspection 1. DISCONNECT VACUUM HOSES FROM EGR VACUUM MODULATOR 2. INSPECT EGR VACUUM MODULATOR OPERATION (a) Block ports P and R with your finger. (b) Blow air into port Q and check that the air passes through to the air filter side freely. (c) Start the engine and maintain speed at 3,000 rpm. (d) Repeat the above test. Check that there is a strong resistance to air flow. If operation is not as specified, replace the EGR vacuum modulator. 15. RECONNECT VACUUM HOSES TO EGR VACUUM MODULATOR Page 2849 Finding A Short Circuit 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: 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) Voltage Check Page 930 Overdrive Switch: Electrical Diagrams System Diagnosis Air/Fuel Mixture: Testing and Inspection 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 systems, etc. should be properly connected. f. Sequential Multiport Fuel Injection (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 APPROXIMATELY 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. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. a. Check heated oxygen sensor operation. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4464 Brake Pedal Assy: Testing and Inspection ON-VEHICLE INSPECTION 1. Check pedal height. Pedal height from asphalt seat: 154.6 - 164.6 mm (6.087 - 6.480 inch) 2. If necessary, adjust pedal height. a. Disconnect the connector from the stop light switch. b. Loosen the stop light switch lock nut and remove the stop light switch. c. Loosen the push rod lock nut. d. Adjust the pedal height by turning the pedal push rod. e. Tighten the push rod lock nut. Torque: 25 Nm (19 ft. lbs.) f. Install the stop light switch and turn it until it lightly contacts the pedal stopper. g. Turn the stop light switch back one turn. h. Check the clearance A) between the stop light switch and pedal. Clearance: 0.5 - 2.4 mm (0.020 - 0.094 inch) i. Tighten the stop light switch lock nut. j. Connect the connector to the stop light switch. k. Check that the stop lights come on when the brake pedal is depressed, and go off when the brake pedal is released. l. After adjusting the pedal height, check the pedal freeplay. HINT: If clearance A) between the stop light switch and the pedal stopper has been adjusted correctly, the pedal freeplay will meet the specifications. Page 2202 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4434 Key to Diagrams Power Window Page 4102 Finding A Short Circuit 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: 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) Voltage Check Page 1692 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2793 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2923 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4852 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1958 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1050 Drive Belt: Tools and Equipment Toyota Serpentine Belt Wrench AST tool# TOY 1914 The TOY 1914 is a Toyota serpentine belt wrench that is equipped with 14mm and 19mm, 12 point secured attachments. Applications: 1998-2005 Corolla, 2004 Matrix, 2008 Highlander V6 (Non Hybrid), 2002 RAV4 and 4.7L/5.7L V8 used in Tundra and Sequoia through 2008. - Lightweight and Slim design - Equipped with 14mm and 19mm, 12 point securing attachments - Works on most Toyota applications (except Hybrids) Contact AST for pricing. Page 3215 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1501 Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 108 kPa 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01 (09231-10110-01) 6. When using the radiator cap tester, tilt it more than 30 degrees. Page 4062 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 537 Ground Points 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. How to Read Power Source Page 2149 Brake Signal: Testing and Inspection DTC P1520 Stop Light Switch Signal Malfunction CIRCUIT DESCRIPTION This signal is used to detect when the brakes have been applied. The BK signal voltage is the same as the voltage supplied to the stop lights. The BK 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.) DETECTING CONDITION WIRING DIAGRAM Step 1 Testing and Inspection EGR Control Solenoid: Testing and Inspection INSPECTION 1. REMOVE VSV (a) Remove the bolt. (b) Disconnect the connector and 2 vacuum hoses from the VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between terminals. Resistance: 33 - 39 ohms at 20°C (68°F) If there is no continuity, replace the VSV. 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. 4. INSPECT VSV OPERATION (a) Check that air does not flow from ports E to F. Page 2608 CHART 14 Page 1296 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 2078 Compression Check: Testing and Inspection 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 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Page 738 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 935 Step 1 Page 3684 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 551 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 2228 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3999 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 3651 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2325 Knock Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1625 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2242 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4694 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 981 Alignment: Specifications Vehicle Height: Front* ................................................................................................................................................... ................................................ 45 mm (1.77 inch) Rear** ................................................................... ............................................................................................................................... 51 mm (2.01 inch) Camber ................................................................................................................................................ ........................................... 0°18' ± 45' (0.3° ± 0.75°) Right-Left Error .................................................................................................................................... ................................................. 30' (0.5°) Or Less Caster .................................................................................................................................................. ........................................... 1°24' ± 45' (1.4° ± 0.75°) Right-Left Error .................................................................................................................................... ................................................. 30' (0.5°) Or Less Steering Axis Inclination ............................................................................................................................................................ 10°24' ± 45' (10.4° ± 0.75°) Right-Left Error .................................................................................................................................... ................................................. 30' (0.5°) Or Less Toe In: Total .............................................................................................................................................. 0°12' ± 12' (0.2° ± 0.2°), 2 ± 2 mm (0.08 ± 0.08 inch) Rack End Length Difference .......................................................................................................................................... 1.5 mm (0.059 inch) Or Less Wheel Angle: Maximum: Inside Wheel .................................................................................................................................. 37°05' (35°05' - 38°05'), 37.08° (35.08° - 38.08°) Outside Wheel ....................................................... .............................................................................................................................. 32°20' (32.33°) *A-B A: Ground Clearance Of Spindle Center. B: Ground Clearance Of Lower Suspension Arm Bolt Center. ** C - D C: Ground Clearance Of Rear Axle Shaft Center. D: Ground Clearance Of Leaf Spring Front Hanger Pin Center. Page 311 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1726 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 4783 a. Remove the 2 screws. Torque: 1.4 kW type: 5.9 N.m (60 kgf.cm, 52 in.lbf) 2.0 kW type: 9.3 N.m (93 kgf.cm, 82 in.lbf) b. Remove these parts from the magnetic switch assembly: 1. Starter housing 2. Return spring 3. Clutch assembly 4. Idler gear 5. Bearing 3. REMOVE STEEL BALL Using a magnetic finger, remove the steel ball from the clutch shaft hole. 4. REMOVE BRUSH HOLDER a. Remove the 2 screws and end cover from the field frame. Torque: 1.4 kW type: 1.5 N.m (15 kgf.cm, 13 in.lbf) 2.0 kW type: 3.8 N.m (38 kgf.cm, 34 in.lbf) Page 3140 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4021 Finding A Short Circuit 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: 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) Voltage Check Testing and Inspection Testing and Inspection Audible Warning Device Control Module: Testing and Inspection Light-On Warning System: INSPECT INTEGRATION RELAY OPERATION a. Connect the positive (+) lead from the battery to terminal 12 and the negative (-) lead to terminal 7. b. Connect the positive (+) lead from the battery to terminal 4 and the negative (-) lead to terminal 5. c. Check that the buzzer does not sound when terminal 4 or 5 is connected to the positive (+) lead. d. Check that the buzzer does not sound when disconnecting terminal 4 or 5. If operation is not as specified, replace the relay. Diagram Information and Instructions ABS Main Relay: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2996 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1894 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1484 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. Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1119 j. With the engine idling and valve fully opened, turn the steering wheel to full lock. Minimum fluid pressure: 8,336 kPa (85 kgf/cm2,1,209 psi) NOTICE: ^ Do not maintain lock position for more than 10 seconds. ^ Do not let the fluid temperature become too high. k. Disconnect the SST l. Connect the pressure feed tube. m. 5VZ-FE Engine: Install the air cleaner and 3 bolts. n. Bleed the power steering system. Page 1345 c. Install No.2 damper with the bolt. Torque: 27 Nm (270 kgf.cm, 20 ft. ft. lbs.) d. Remove a pin from the No.2 chain tensioner and free the plunger. 4. 2RZ-FE: INSTALL OIL JET Install a new gasket and the oil jet with the bolt. Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.) 5. 2RZ-FE: INSTALL CRANKSHAFT POSITION SENSOR ROTOR Install the rotor to the crankshaft with the front mark (cavity) of the rotor facing forward. 6. INSTALL NO.1 TIMING CHAIN TENSIONER SLIPPER AND NO.1 VIBRATION DAMPER a. Install the No.1 damper with the bolt and nut. Torque: 29 Nm (300 kgf.cm, 22 ft. lbs.) b. Install the slipper with the bolt. Torque: 27 Nm (270 kgf.cm, 20 ft. lbs.) c. Check that the slipper moves smoothly. 7. INSTALL CRANKSHAFT TIMING GEAR Page 3689 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 2644 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4237 Page 3049 Page 3067 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2702 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4383 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3368 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4015 no continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Page 3980 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3702 Overdrive Switch: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3378 Shift Indicator: Description and Operation Electronically Controlled Transmission and A/T Indicator Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Capacity Specifications Fluid - Differential: Capacity Specifications Differential Oil Specified amount 2RZ-FE ................................................................................................................... .......................................................... 1.35L (1.43 Qt) 3RZ-FE/5VZ-FE 4WD Extra Long Model ........ .............................................................................................................................................................. .......... 2.45L (2.58 Qt) With Locking Differential: Short Model ............................................................ ...................................................................................................................................... 2.65L (2.80 Qt) Extra Long Model .......................................................................................................................... ............................................................... 2.95L (3.18 Qt) Less Locking Differential ............................ .................................................................................................................................................. 2.55L (2.69 Qt) Page 1975 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3644 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Upper Valve Body Valve Body: Locations Upper Valve Body Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 384 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2645 Page 3210 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3696 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2311 Idle Speed/Throttle Actuator - Electronic: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE IAC VALVE Remove the 4 screws, IAC valve and gasket. INSTALLATION 1. INSTALL IAC VALVE (a) Place a new gasket on the throttle body. (b) install the IAC valve with the 4 screws. 2. INSTALL THROTTLE BODY Page 2895 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 2328 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1339 a. Remove the 2 water bypass pipe nuts. b. Remove the 2 timing chain cover bolts. c. Remove the 9 bolts and 2 nuts. d. Using a plastic faced hammer, loosen the chain cover and remove the timing chain cover and 3 gasket. 15. REMOVE NO.1 TIMING CHAIN AND CAMSHAFT TIMING GEAR 16. REMOVE CRANKSHAFT TIMING GEAR HINT: If necessary, remove the gear with SST and crankshaft pulley bolt. SST 09950-40011 (09951-04010, 09952-04010, 09953-04010, 09954-04010, 09955-04060) Page 4621 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Diagram Information and Instructions Wheel Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1980 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3471 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2847 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 777 Ground Points 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. How to Read Power Source Page 1551 Exhaust Manifold: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Removal and Installation. Page 4316 ABS Main Relay: Description and Operation 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. Fail safe function: If trouble occurs in the ABS relay circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 2188 Finding A Short Circuit 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: 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) Voltage Check Page 4071 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4442 Finding A Short Circuit 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: 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) Voltage Check Page 3281 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4443 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4841 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 799 Ground Points 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. How to Read Power Source Page 3027 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 563 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1336 REMOVAL 1. REMOVE ENGINE UNDER COVER 2. DRAIN ENGINE OIL 3. 4WD: REMOVE FRONT DIFFERENTIAL AND DRIVE SHAFTS ASSEMBLY 4. REMOVE DRIVE BELT FOR GENERATOR, FAN WITH FLUID COUPLING AND WATER PUMP PULLEY 5. REMOVE CYLINDER HEAD ASSEMBLY 6. w/ A/C: DISCONNECT A/C COMPRESSOR AND BRACKET a. Remove the 4 bolts, and disconnect the compressor from the bracket. HINT: Put aside the compressor, and suspend it. Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 88 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 319 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 732 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove speed sensor. a. Disconnect the speed sensor connector. b. Remove the 2 (4WD) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (71 inch lbs.) Side rail: 13 Nm (9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. Page 4242 Step 2 Step 3 INSPECTION PROCEDURE Page 3551 Ground Points 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. How to Read Power Source Page 4029 Shift Indicator: Description and Operation Electronically Controlled Transmission and A/T Indicator Previous automatic transmissions 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 governor pressure and lock-up pressure through the solenoid valve. Control of the solenoid valve by the engine control module 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 SP2+ 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 1 of the Electronically Controlled Transmission 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 1 of the Electronically Controlled Transmission Solenoid to GROUND, and from TERMINAL S2 of the Engine Control Module to TERMINAL 2 of the Electronically Controlled Transmission 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 continuous 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 3 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 BK of the engine control module. The engine control module operates and continuous to the lock-up solenoid is cut. Restraints - OCS System Initialization Seat Occupant Sensor: Technical Service Bulletins Restraints - OCS System Initialization COLLISION REPAIR INFORMATION FOR THE COLLISION REPAIR PROFESSIONAL TITLE: SRS OCCUPANT CLASSIFICATION SYSTEM INITIALIZATION SECTION: ELECTRICAL BULLETIN # 177 MODELS: ALL EQUIPPED TOYOTA LEXUS and SCION MODELS DATE: MARCH 2010 Models equipped with a Supplemental Restraint System (SRS) Occupant Classification System (OCS) will enable or disable the passenger front and side airbags based on seat occupancy passenger weight and seat belt latch engagement. If an equipped vehicle sustains collision damage or if the front passenger seat or any of the OCS components are serviced the SRS Malfunction Indicator Light (MIL) may illuminate setting a Diagnostic Trouble Code (DTC). NOTE: It is necessary to diagnose and repair the root cause of a SRS or OCS DTC before initializing the OCS system. If SRS and OCS DTC's are not cleared the system may not operate properly. Be sure to check and clear DTC's and perform OCS initialization per repair manual instructions with a Techstream Special Service Tool (SST) or capable diagnostic tester. Any of the following conditions could set a DTC illuminate the SRS MIL or cause the PASSENGER AIRBAG light to indicate incorrectly regardless of occupancy: ^ The OCS Electronic Control Unit (ECU) is replaced ^ Accessories such as a seatback tray are installed on the passenger seat ^ The passenger seat is removed and replaced or reinstalled ^ The vehicle is involved in an accident or collision Model-specific repair manuals can be accessed through the Technical Information System (TIS) www.techinfo.toyota.com Page 2378 CHART 18 CHART 19 Page 4412 Page 4131 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Ford Made System Brake Switch (Cruise Control): Description and Operation Ford Made System CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit1 terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. Page 1041 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 337 Finding A Short Circuit 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: 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) Voltage Check Page 4334 Page 4184 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3166 Ground Points 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. How to Read Power Source Page 2533 Finding A Short Circuit 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: 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) Voltage Check Page 3316 Shift Solenoid: Electrical Diagrams Page 951 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 961 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 2715 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2231 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 700 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4376 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4851 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 941 O/D OFF indicator light remains ON Page 731 Ground Points 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. How to Read Power Source Page 4225 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Specifications Camshaft Gear/Sprocket: Specifications Camshaft Timing Gear Bolt 73.5 Nm (54 ft.lb) Page 987 b. Loosen the tie rod end lock nuts. c. 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. d. Make sure that the lengths of the right and left rack ends are the same. Rack end length difference: 1.5 mm (0.059 inch) or less e. Tighten the tie rod end lock nuts. Torque: 55 Nm (560 kgf-cm, 41 ft. lbs.) f. Place the boots on the seats and install the clips. HINT: Make sure that the boots are not twisted. g. Inspect the wheel angle. Turn the steering wheel fully and measure the turning angle. Wheel turning angle: If the right and left wheel turning angles differ from the specified value, readjust the toe-in and wheel angle within the specified value. At this time, the right and left error lengths of the rack end may be less than 1.5 mm (0.059 inch). Page 1995 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 358 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3656 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 540 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3237 Finding A Short Circuit 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: 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) Voltage Check Page 1334 Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4771 2.0 kW type: 100 A or less at 11.5 V Page 1699 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2381 CHART 21 Page 1584 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 516 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2435 Finding A Short Circuit 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: 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) Voltage Check Page 1062 Oil Filter: Tools and Equipment Toyota Oil Filter Wrench Set AST tool# TOY 300 This set includes our tool numbers TOY640, TOY730, and M0219. With the TOY300 you have every gas engine Toyota/Lexus model covered between 1980 and 2009. - Covers all Toyota and Lexus vehicles 1980-2009, based on factory filters. Contact AST for pricing. Assenmacher Specialty Tools 1-800-525-2943 This Kit Contains the Following Tools: TOY 640 - Toyota Oil Filter Wrench Page 1650 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 924 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1189 Compression Check: Testing and Inspection 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 2. REMOVE INTAKE AIR CONNECTOR 3. DISCONNECT HIGH-TENSION CORDS FROM SPARK PLUGS NOTICE: Pulling on or bending the cords may damage the conductor inside. 4. REMOVE SPARK PLUGS 5. CHECK CYLINDER COMPRESSION PRESSURE a. Insert a compression gauge into the spark plug hole. b. Fully open the throttle c. 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: 1,230 kPa (12.5 kgf/cm2, 178 psi) or more Minimum pressure: 880 kPa (9.0 kgf/cm2, 127 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, chances are that the piston rings and/or cylinder bore are worn or damage. - If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the gasket. 6. REINSTALL SPARK PLUGS Torque: 19 Nm (200 kgf.cm, 14 ft. lbs.) 7. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 8. REINSTALL INTAKE AIR CONNECTOR Page 2906 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 2506 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 1101 Fluid - Differential: Fluid Type Specifications DIFFERENTIAL OIL API GL - 5 Hypoid Gear Oil: Above - 18° C (0° F) ............................................. ................................................................................................................................................. SAE 90W Below - 18° C (0° F) .................................................................................................................... ...................................................... SAE 80W - 90 or 80W Page 1852 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 953 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4186 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Application and ID Valve Spring Shim: Application and ID Page 611 Knock Sensor: Description and Operation 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. Page 4166 Step 4 O/D OFF indicator light does not light up Step 1 Step 2 Page 1753 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Locations Power Distribution Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 233 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4641 Ground Points 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. How to Read Power Source Page 938 Step 1 Step 2 Page 2399 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Specifications Wheel Cylinder: Specifications Bleeder Plug 96 in.lb Wheel Cylinder To Backing Plate 84 in.lb Page 585 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2922 Key to Diagrams Power Window Page 2629 Page 1814 Page 2603 CHART 7 Page 2464 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Front Page 136 EFI Main Relay: Testing and Inspection INSPECTION 1. REMOVE EFI MAIN RELAY (Marking: EFI) LOCATION: In the engine compartment relay box. 2. INSPECT EFI MAIN RELAY CONTINUITY (a) Using an ohmmeter, check that there is continuity between terminals 86 and 85. If there is no continuity, replace the relay. (b) Check that there is no continuity between terminals 87 and 30. If there is continuity, replace the relay. 3. INSPECT EFI MAIN RELAY OPERATION (a) Apply battery positive voltage across terminals 86 and 85. (b) Using an ohmmeter, check that there is continuity between terminals 87 and 30. If operation is not as specified, replace the relay. 4. REINSTALL EFI MAIN RELAY Locations Overdrive Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Locations Page 374 INSPECTION PROCEDURE Page 2710 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 2543 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1793 CHART 8 CHART 9 Page 2402 Key to Diagrams Power Window Locations Page 3417 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. On-Vehicle Inspection Throttle Body: Testing and Inspection On-Vehicle Inspection ON-VEHICLE INSPECTION 1. INSPECT THROTTLE BODY (a) Check that the throttle linkage moves smoothly. Port Identification Reference (b) Check the vacuum at each port. - Start the engine. - Check the vacuum with your finger. 2. INSPECT THROTTLE POSITION SENSOR (a) Disconnect the sensor connector. (b) Apply vacuum to the throttle opener. Ohmmeter Connection Page 1818 Page 4588 Page 2268 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3197 Page 3117 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4776 b. Using a press, press in a new front bearing. 17. INSPECT REAR BEARING Turn the bearing by hand while applying inward force. If resistance is felt or the bearing sticks, replace the bearing. 18. IF NECESSARY, REPLACE REAR BEARING a. Using SST, remove the bearing. SST 09286-46011 b. Using a press, press in a new rear bearing. NOTE: Be careful of the bearing installation direction. SST 09201-41020 19. DO PULL-IN COIL OPEN CIRCUIT TEST Using an ohmmeter, check that there is continuity between terminals 50 and C. If there is no continuity, check and replace the magnetic switch. Page 1243 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 4628 Finding A Short Circuit 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: 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) Voltage Check Page 1764 Page 4558 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4531 4. Remove these parts: - Clip. - 2 pins. - Anti-rattle spring. - 2 pads. - 4 anti-squeal shims. INSTALLATION Installation is in the reverse order of removal. After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. Page 2717 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1525 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 4288 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Diagnostic Trouble Code Tests and Associated Procedures Idle Speed/Throttle Actuator - Electronic: Diagnostic Trouble Code Tests and Associated Procedures 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. DETECTING CONDITION WIRING DIAGRAM Page 607 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1700 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4804 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Relay Blocks Relay Blocks Page 275 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3226 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4007 Locations-J/B No.3 Behind The Instrument Panel Left (Fig 22) Page 776 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1677 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Locations Backup Lamp Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3420 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 313 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4303 Ground Points 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. How to Read Power Source Page 1823 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1511 Ground Points 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. How to Read Power Source Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4292 Finding A Short Circuit 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: 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) Voltage Check Page 4411 Page 3365 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4800 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Junction Block and Wire Harness Connector Page 3918 REAR AXLE SHAFT Page 1129 Refrigerant Oil: Fluid Type Specifications Type ND-OIL 8 Page 3407 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2866 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 4726 Parking and Paint Protection ^ Storage areas should be paved, well lit and secure. If your off-site storage lot is not paved, spread gravel down to minimize mud and dust. Be sure vehicles are driven carefully when moving them to or from a long-term lot. This will help minimize damage to the paint finish from road grit or gravel. ^ Park vehicles from right to left at least three feet apart. Leave enough space front and rear to easily walk between rows. ^ HVAC vent controls should be set to "Recirc" to minimize dust and odor intrusion. ^ Make sure the plastic door edge protectors are in place and fold in the side view mirror (if applicable). ^ Anti-rust covers or anti-rust film should remain on vehicle during storage 1. Anti-Rust Covers (behind wheel) should be removed at PDS. 2. Anti-Rust Film (applied to wheel) should be removed just prior to customer delivery. ^ Wash vehicles frequently. Battery ^ Turn off all electrical accessories, make sure windows and sunroof are closed and check that the transmission is in "park" (first or reverse for manual transmission vehicles). Do not apply the parking brake. ^ Test batteries monthly (more often in high heat or cold areas), using the Digital Battery System ^ Analyzer (P/N 00002-V8150-KIT). Refer to TSB PG001-06, "Battery Maintenance for In Stock Vehicles and Pre-Delivery" for complete battery maintenance procedures. ^ To reduce battery drain during long-term storage, remove the battery ground (-) cable of each vehicle and reinstall just before delivery to the customer. Locate the current PDS TSB on TIS for complete details. ^ If a hybrid vehicle is put into storage, the state of charge (SOC) of it's battery and auxiliary battery will gradually decrease. To prevent the auxiliary battery from becoming discharged during storage, proper maintenance is necessary. Refer to TSB "Maintenance for HV & Auxiliary Batteries" for procedure and additional information. Tire Inflation Pressure If the vehicle is parked for long periods without being moved, a flat spot may develop on each tire surface in contact with the ground, even if the tires are inflated to specification. Tire inflation pressure should be checked once a month. Tire inflation pressure for storage only: 45 psi. Parts Rust If the vehicles in your storage area are exposed to a sea breeze and/or a significant precipitation corrosion with rust in some parts may occur. If rust is found remove it and treat it by applying rust inhibitor to prevent recurrence. Engine Starting and Vehicle Movement If the vehicle is stored over an extended period of time starting and running the engine periodically will ensure smooth running operation. 1. Start and operate the engine at an engine speed under 1,500 RPM for 15 minutes or longer. This also eliminates moisture in the exhaust system. NOTE Be sure to allow sufficient clearance at the rear of the vehicle to prevent other vehicles stored behind from getting damaged by exhaust gas. 2. Move the vehicle at least 30 feet to lubricate the transmission and differential and prevent tire flat-spot damage. 3. Raise engine speed above 3,000 RPM 10 times to eliminate moisture from the exhaust. A/C Compressor Lubrication To minimize the possibility of damage to the A/C compressor while storing a vehicle perform the following recommended maintenance procedures at Page 4738 Battery Replacement If a vehicle battery needs to be replaced for a warrantable condition, complete a Warranty Battery Label and affix it to the failed battery for proper warranty parts and claim processing. Include the Vehicle Identification Number ("IN) and warranty code on the Warranty Battery Label. Battery Maintenance Recommended Battery Maintenance: In addition to this new pre-delivery battery test, a monthly battery inspection is still required for stored vehicles. If your dealership is located in an area subject to extreme temperatures (hot or cold), periodic maintenance may need to be performed more frequently. To reduce parasitic battery drain on vehicles in storage for one week or more, the negative (-) battery cable should always be disconnected to reduce battery discharge. When the negative (-) battery cable is reconnected, please check and reset electrical components, such as the clock, radio, etc., and re-initialize all applicable systems/functions. Refer to the appropriate model and year service bulletins for specific details. For example: ^ TSB No. PD008-05, "Power System Initialization During PDS" (2005 model year) ^ TSB No. PDO14-06, "Power System Initialization During PDS" (2006 model year) Page 1114 Power Steering Fluid: Capacity Specifications Power Steering Fluid: Total ..................................................................................................................................................... .......................................... 0.8 liters (0.9 US Qts.) Page 3652 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location System Diagnosis Air/Fuel Mixture: Testing and Inspection 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 systems, etc. should be properly connected. f. Sequential Multiport Fuel Injection (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 APPROXIMATELY 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. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. a. Check heated oxygen sensor operation. Service and Repair Pinion Flange: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Differential; Service and Repair. Page 2616 Page 3768 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4403 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2977 Fuel Tank: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. INSPECTION INSPECT FUEL TANK AND LINE Page 2956 Fuel Pump Relay: Testing and Inspection INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY (a) Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION (a) Apply battery positive voltage across terminals STA and E1. (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. (c) Apply battery positive voltage across terminals +B and FC. (d) Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 436 Refrigerant Pressure Sensor / Switch: Service and Repair REMOVAL 1. REMOVE EVAPORATOR 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 mounted 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. INSTALLATION Installation is in the reverse order of removal. Page 2377 CHART 16 CHART 17 Page 1372 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Specifications Brake Fluid: Specifications Required Brake Fluid SAE DOT3 Page 4025 Electronically Controlled Transmission (Part 2 Of 3) Page 1522 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 764 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2635 Key to Diagrams Power Window Page 2427 Key to Diagrams Power Window Locations Power Distribution Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2148 Brake Signal: Description and Operation Stop Light Switch Signal Engine 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.). Automatic Transaxle 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 signal to ECM. Then the ECM cancels operation of the lock-up clutch while braking is in progress. Page 839 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2429 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3828 b. A340F: Pry up both pipe ends with a large screwdriver and remove the pipe. 7. DISCONNECT CONNECTORS FROM EACH SOLENOID VALVES 8. REMOVE VALVE BODY a. A340E: Remove the 17 bolts. Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) b. A340F: Remove the 16 bolts. Bolt length: Bolt A: 23 mm (0.91 inch) Bolt B: 32 mm (1.26 inch) Page 3447 Page 697 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4017 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2973 Page 78 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 331 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4574 Load Compensator: Testing and Inspection ON-VEHICLE INSPECTION 1. Set rear axle load. Rear axle load (includes vehicle weight): 2WD 700 kg (1,543 lbs.) 4WD 850 kg (1,874 lbs.) 2. Install Load Sensing Proportioning & By-Pass Valve (LSP & BV) gauge Special Service Tool (SST) 09709-29018 or equivalent and bleed air. 3. Raise front brake pressure to 7,845 kPa (1,138 psi) and check rear brake pressure. Rear brake pressure: 2WD 4,913 ± 490 kPa (713 ± 71 psi) 4WD 4,383 ± 490 kPa (636 ± 71 psi) HINT: The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect, adjust the fluid pressure. 4. If necessary, adjust fluid pressure. a. Adjust the length of the No.2 shackle. Low pressure-Lengthen A High pressure-Shorten A Initial set: Page 4512 Brake Shoe: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4136 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.). 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. Page 1703 Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2833 EGR Temperature Sensor: Testing and Inspection INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 K ohms at 50°C (122°F) 11 - 16 K ohms at 100°C (212°F) 2 - 4 K ohms at 150°C (302°F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 2842 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Locations Page 4016 Shift Indicator: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 285 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3441 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 711 Key to Diagrams Power Window Page 2657 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2727 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2181 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3274 Ground Points 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. How to Read Power Source Page 4175 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 24) Parts Location Parts Location Page 4894 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 984 VZN195L model If the steering axis inclination is not within the specified value, after the camber and caster have been correctly adjusted, recheck the steering knuckle and front wheel for bearing or looseness. 4. ADJUST CAMBER AND CASTER a. Loosen the front and/or rear adjusting cam nuts. Page 2031 Page 2735 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1464 Heater Control Valve: Service and Repair REMOVAL 1. DRAIN ENGINE COOLANT FROM RADIATOR HINT: It is not necessary to drain out all the coolant. 2. DISCONNECT WATER VALVE CONTROL CABLE FROM WATER VALVE HINT: At the time of installation, please refer to the following item. For installing the control cable, refer to "INSTALLATION" of HEATER CONTROL ASSEMBLY. 3. DISCONNECT WATER HOSES a. Using pliers, grip the claws of the clip and slide the clip along the hose. b. Disconnect the water hose. HINT: At the time of installation, please refer to the following item. Install the hose clip in the position, as shown in the illustration. 4. REMOVE WATER VALVE Remove the bolt and water valve. INSTALLATION Page 681 Oxygen Sensor: Description and Operation 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 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 in 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 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 temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 158 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3592 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2321 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1502 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Plastic Cap, 108 kPa 1. Remove coolant and any foreign material on 0-ring "A." 2. Check that 0-ring "A" is not deformed, cracked, or swollen. 3. Apply engine coolant to 0-ring "A" and rubber point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 4. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 Page 514 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2330 Finding A Short Circuit 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: 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) Voltage Check Page 2252 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2265 Key to Diagrams Power Window Page 2463 Air Flow Meter/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1669 Ground Points 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. How to Read Power Source Page 3478 Shift Solenoid: Description and Operation DESCRIPTION Shift Solenoid 1-2 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.). 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. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunctioning, hydraulic control cannot be performed electronically and must be done manually. Shift Solenoid Valve SL 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. Page 3465 Ground Points 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. How to Read Power Source Page 2976 Fuel Tank: Vehicle Damage Warnings PRECAUTION 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the computer will be erased when the negative (-) terminal cable is disconnected. Therefore, if necessary. read the diagnosis before disconnecting 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. Always use new gaskets when replacing the fuel tank or component parts. 5. Apply the proper torque to all parts tightened. Diagram Information and Instructions Oxygen Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 931 Page 4805 Locations-R/B No.2-Engine Compartment Left (Fig 19) Splice Points Splice Points Page 327 Ground Points 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. How to Read Power Source Page 3544 Specifications Brake Caliper: Specifications Bleeder Plug 96 in.lb Caliper To Steering Knuckle 90 ft.lb Page 2189 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3375 Electronically Controlled Transmission (Part 3 Of 3) Page 2098 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2270 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 745 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 2683 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4084 Step 3 Page 2204 Starter Signal: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3167 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 24 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2224 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 47 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4135 Shift Solenoid: Description and Operation DESCRIPTION Shift Solenoid 1-2 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.). 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. The ECM also turns the shift solenoid valve SL OFF at the same time. If both solenoids are malfunctioning, hydraulic control cannot be performed electronically and must be done manually. Shift Solenoid Valve SL 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. Page 2359 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ 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 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Page 2960 Fuel Return Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. INSPECTION INSPECT FUEL TANK AND LINE Page 2362 Page 4618 Ground Points 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. How to Read Power Source Page 2141 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Standard Value of ECM Terminals Engine Control Module: Testing and Inspection Standard Value of ECM Terminals Chart 1 Of 2 Page 1738 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 305 Ground Points 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. How to Read Power Source Page 2221 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1649 Key to Diagrams Power Window Page 633 Page 3115 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 855 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 1881 Diagram Information and Instructions Brake Switch (Cruise Control): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3738 Page 3653 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2736 Key to Diagrams Power Window Page 785 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Testing and Inspection Power Mirror Switch: Testing and Inspection INSPECT MIRROR SWITCH CONTINUITY Left side: Right side: If continuity is not as specified, replace the switch. Page 2244 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3178 Page 2734 Ground Points 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. How to Read Power Source Page 3807 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 3618 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4310 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Specifications Brake Shoe: Specifications Lining Thickness: Standard 0.236 in Minimum 0.039 in Drum To Shoe Clearance 0.024 in Page 1458 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 4287 ABS Light: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 312 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3148 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 41 Step 2 Step 3 INSPECTION PROCEDURE Page 415 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4008 Locations-J/B No.3 Behind The Instrument Panel Center (Fig 24) Parts Location Parts Location Page 778 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3128 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 1410 WATER PUMP AND RELATED COMPONENTS Page 3427 Step 3 Diagram Information and Instructions Wheel Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2566 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4757 a. 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) b. Check that SST (A) is secured to the rotor shaft. c. Mount SST (C) in a vise. d. install the generator to SST (C). e. To loosen the pulley nut, turn SST (A) in the direction shown in the illustration. NOTE: 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). g. Turn SST (B) and remove SST (A and B). h. Remove the pulley nut and pulley. 5. REMOVE RECTIFIER END FRAME Page 3951 Drive/Propeller Shaft: Testing and Inspection PROBLEM SYMPTOMS TABLE Use the table 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. Page 879 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 164 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2357 A/F and 02 Sensor Identification Page 2371 CHART 8 CHART 9 Page 2999 Page 2206 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2516 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 3310 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4256 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3753 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1849 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4545 Brake Proportioning/Combination Valve: Pressure, Vacuum and Temperature Specifications SERVICE SPECIFICATIONS Rear Axle Load (Includes Vehicle Weight) ......................................................................................................................................... 850 kg (1,874 lbs.) Front Brake Pressure .......................................................................................................................... ........................................ 7,845 kPa (1,138 psi) Rear Brake Pressure ............................................................................................................................................. 4,383 ± 490 kPa (636 ± 71 psi) Testing and Inspection Power Steering Pressure Switch: Testing and Inspection INSPECTION 1. TURN AIR CONDITIONING SWITCH OFF. 2. CHECK IDLE-UP. a. Start engine and run it at idle. b. Fully turn the steering wheel. c. Check that the engine rpm decreases when the vacuum hose of the air control valve is pinched. d. Check that the engine rpm increases when the hose is released. Page 3004 Step 1 Step 2 Page 1962 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4458 Loosen/Tighten Bleeder Plug 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) 11 Nm (8 ft. lbs.) 5. Repeat procedure for each wheel. 6. Bleed Load Sensing Proportioning & By-Pass Valve (LSP & BV). LOAD SENSING PROPORTIONING AND BY-PASS VALVE (LSP & BV) ON-VEHICLE INSPECTION HINT: Pre runner is described below. RZN191L-TRPDKAB, RZN196LCRPDKAB, VZN195L-CRPDKAB 1. SET REAR AXLE LOAD Rear axle load (includes vehicle weight): 2. INSTALL LSP & BV GAUGE (SST) AND BLEED AIR SST 09709-29018 3. RAISE FRONT BRAKE PRESSURE TO 7,845 kPa (8Q kgf/cm2, 1,138 psi) AND CHECK REAR BRAKE PRESSURE Page 2595 Locations Page 1816 CHART 29 Specifications Connecting Rod Bearing: Specifications Connecting Rod Clearance: Oil: Standard ................................................................................................................................................ 0.030 0.055 mm (0.0012 - 0.0022 inch) U/S 0.25 ................................................................................................................................................ 0.031 0.071 mm (0.0012 - 0.0026 inch) Maximum ........................................................................................ ................................................................................... 0.10 mm (0.0039 inch) Thrust: Standard ................................................................................................................................................ 0.160 0.312 mm (0.0063 - 0.0123 inch) Maximum ........................................................................................ ................................................................................... 0.35 mm (0.0138 inch) Service and Repair Oil Filter: Service and Repair For information regarding the service and repair of this component, please refer to Oil; Service and Repair. Diagram Information and Instructions Knock Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Testing and Inspection Brake Light Switch: Testing and Inspection w/o Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. W/ Cruise Control: INSPECT STOP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 1766 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 1150 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1909 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 980 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 626 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction 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. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description 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 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required 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 Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 1333 Timing Chain: Service and Repair Electrode Gap Specification Spark Plug: Specifications Electrode Gap Specification Electrode Gap Correct Gap ......................................................................................................................................... ........................................................................ 0.8 mm Page 709 Ground Points 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. How to Read Power Source Page 3620 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3165 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4351 Finding A Short Circuit 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: 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) Voltage Check Page 2592 2. Start the engine. 3. Perform the drive pattern to run and complete the Oxygen Sensor (O2S) Monitor. HINT: The 02S Monitor is completed when the following conditions are met: ^ Two (2) minutes or more passed after the engine start. ^ The Engine Coolant Temperature (ECT) is 167°F (75°C) or more. ^ Cumulative running time at 30 mph (48 km/h) or more exceeds 6 minutes. ^ Vehicle is in closed loop. ^ 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 6mph (10km/h). F. Repeat steps B - E at least twice in one driving cycle. Accessing O2S Test Results 1. On the Diagnostic Tester* screen, select the following menus: ^ DIAGNOSTICS ^ CARB OBD II Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 3625 Overdrive Indicator Lamp: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 800 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 765 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4516 Wheel Cylinder: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 4235 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2372 CHART 10 Page 2004 Finding A Short Circuit 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: 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) Voltage Check Page 367 Clutch Switch: Electrical Diagrams Page 848 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2388 Page 175 Air Bag Control Module: Description and Operation The airbag sensor assembly is mounted on the floor inside the center cluster. The airbag sensor assembly consists of a airbag sensor, safing sensor, diagnosis circuit, ignition control and drive circuit,etc.. It receives signals from the airbag sensor assembly and judge whether the SRS must be activated or not and diagnosis system malfunctions. Page 3552 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4297 Step 3 INSPECTION PROCEDURE Troubleshooting in accordance with the chart above for each trouble symptom. Page 4157 Page 3813 RETAINER SPECIFICATIONS Page 3922 Using a snap ring expander, remove the snap ring. 3. REMOVE REAR AXLE SHAFT FROM BACKING PLATE a. Position SST on the backing plate with the 4 nuts. SST 09521-25011 b. Using a press, remove the rear axle shaft and bearing retainer from the backing plate. c. Remove the SST 4. INSPECT AXLE SHAFT Using a dial indicator, measure the runout of the shaft and flange. Maximum shaft runout: 2.0 mm (0.079 inch) Maximum flange runout: 0.1 mm (0.004 inch) If the rear axle shaft or flange are damaged or worn, or if runout is greater than the maximum, replace the rear axle shaft. 5. REMOVE OUTER OIL SEAL Using SST, remove the oil seal. SST 09308-00010 6. REPLACE REAR AXLE BEARING Page 608 Finding A Short Circuit 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: 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) Voltage Check Page 2225 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1632 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2798 Page 2122 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4735 6. Select CHARGING from the Main Menu screen and press the SELECT soft key. 7. Select DIAGNOSTIC from the Charge Menu screen and press the SELECT soft key. 8. Select IN VEHICLE and press the NEXT soft key. 9. Select MODEL and press the NEXT soft key. NOTE: ^ "MODEL" or "STOCK # " MUST be used to receive a warranty code if the tester determines that the battery is bad. ^ "MODEL" and "STOCK # " are linked to custom algorithms and are the most accurate testing procedures. Page 1996 Key to Diagrams Power Window Page 1976 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4096 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1806 CHART 23 Locations Page 2351 Engine Bank Identification Page 3572 Step 3 Page 4290 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2432 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3955 1. INSPECT PROPELLER SHAFT AND INTERMEDIATE SHAFT FOR DAMAGE OR RUNOUT a. Inspect the shafts for wear or damage. b. Using a dial indicator, check the runout of the shafts. Maximum runout: 0.8 mm (0.031 inch) If the shaft runout exceeds the maximum, replace the shaft. 2. INSPECT SPIDER BEARING a. Inspect the spider bearings for wear or damage. b. Using a dial indicator, check the spider bearing axial play by turning the yoke while holding the shaft tightly. Maximum bearing axial play: 0.05 mm (0.0020 inch) If the spider bearing axial play exceeds the maximum, replace the spider bearing. 3. 3-joint type: INSPECT CENTER SUPPORT BEARING FOR WEAR OR DAMAGE Check that the bearing turns freely. If the bearing is damaged, worn, or does not turn freely, replace it. 4. w/ Double cardan joint propeller shaft: INSPECT WITH DOUBLE CARDAN JOINT PROPELLER SHAFT a. Inspect the shaft for wear or damage. b. Inspect the double cardan joint for wear or damage. If any problem is found, replace the propeller shaft assembly. REASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2424 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 696 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 3328 Key to Diagrams Power Window Page 2116 Ground Points 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. How to Read Power Source Page 4649 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3145 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1946 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. ABS/TCS - Zero Point Calibration Information Yaw Rate Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 3735 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 101 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations A/T.P. (Automatic Transmission Parking) Indicator Circuit Shift Indicator: Description and Operation A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. Page 459 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2156 Ground Points 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. How to Read Power Source Page 2491 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Locations Fusible Link: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 154 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3257 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 546 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4000 O/D OFF indicator light remains ON Page 756 Ground Points 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. How to Read Power Source Page 1775 Oxygen Sensor: Technical Service Bulletins Engine Controls - Bank 1/Bank 2 O2 Sensor identification ENGINE EG034-07 Title: ENGINE BANK 1 AND BANK 2 A/F AND O2 IDENTIFICATION Models: '93 - '08 Applicable Models June 28, 2007 The information contained in this TSB supercedes TSB No. EG037-04. TSB No. EG037-04 is now obsolete and should be discarded. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2GR-FSE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FSE, 3UR-FE, 2UZ-FE, 3UZ-FE, 5VZ-FE, and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 4075 Overdrive Switch: Electrical Diagrams Page 2766 Finding A Short Circuit 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: 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) Voltage Check Page 2892 Page 3953 1. 4WD: REMOVE FRONT PROPELLER SHAFT a. Place matchmarks on the propeller shaft and front differential flanges. b. Remove the 4 nuts, bolts and washers. Torque: 74 Nm (750 kgf cm, 54 ft. lbs.) c. Suspend the front side of the propeller shaft. d. Place matchmarks on the propeller shaft and transfer flanges. e. Remove the 4 nuts and washers. Torque: 74 Nm (750 kgf cm, 54 ft. lbs.) f. Remove the front propeller shaft. 2. REMOVE PROPELLER SHAFT (PRE RUNNER) AND REAR PROPELLER SHAFT (4WD) a. Place matchmarks on the propeller shaft, transmission (pre runner) and transfer (4WD) flanges. b. Remove the 4 nuts and washers. Torque: 74 Nm (750 kgf cm, 54 ft. lbs.) c. Place matchmarks on the propeller shaft and rear differential flanges. d. Remove the 4 nuts, bolts and washers. Torque: 74 Nm (750 kgf cm, 54 ft. lbs.) e. 3-joint type: Remove the center support bearing 2 set bolts and 2 plates from the frame crossmember. Torque: 36 Nm (370 kgf cm, 27 ft. lbs.) f. Remove the propeller shaft. DISASSEMBLY NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 4669 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3761 Key to Diagrams Power Window Page 2707 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4441 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4143 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Page 3615 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4654 Acceleration/Deceleration Sensor: Description and Operation CIRCUIT DESCRIPTION This sensor detects deceleration on the vehicle. The sensor signal is used in ABS control. If the sensor functions¢4mtions abnormally. The ECU cuts off current to the ABS control (solenoid) relay and prohibit ABS control¢0m. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2841 Key to Diagrams Power Window Page 1734 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 581 Key to Diagrams Power Window Diagrams Page 3253 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2032 Knock Sensor: Description and Operation 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. Page 2205 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 405 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2164 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2105 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4611 b. Remove the booster and gasket. INSTALLATION 1. Install brake booster. a. Install the booster and a new gasket. b. Install the clevis to the operating rod. c. Install and torque the booster installation nuts. Torque: 13 Nm (9 ft. lbs.) d. Install the clevis pin into the clevis and brake pedal, and install the clip to the clevis pin. e. Install the pedal return spring. 2. Adjust length of booster push rod. a. Install a new gasket on the master cylinder. Set SST On Gasket b. Set the Special Service Tool (SST) 09737-00010 or equivalent, on the gasket, and lower the pin until its tip slightly touches the piston. c. Turn the (SST) upside down, and set it on the booster. d. Measure the clearance between the booster push rod and pin head (SST). Clearance: 0 mm (0 inch) e. Adjust the booster push rod length until the push rod lightly touches the pin head. 3. Install master cylinder. 4. Connect vacuum hose to brake booster. 5. Fill brake reservoir with brake fluid and bleed brake system. 6. Check for fluid leakage. 7. Check and adjust brake pedal. 8. Do operational check. a. Depress the brake pedal several times with the engine off and check that there is no change in the pedal reserve distance. b. Depress the brake pedal and start the engine. If the pedal goes down slightly, operation is normal. Page 1478 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. Page 3191 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 645 CHART 16 CHART 17 Page 1070 Hose/Line HVAC: Tools and Equipment A/C Clamp Remover AST tool# TOY 200 Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4389 Diagnostic Connector - ABS: Electrical Diagrams Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Cooling System - Leak at Radiator Overflow Hose Radiator: Customer Interest Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 1039 - Remove the adjusting shim with a small screwdriver and magnetic finger. b. Determine the replacement adjusting shim size by these Formula or Charts: - Using a micrometer, measure the thickness of the removed shim. - Calculate the thickness of a new shim so that the valve clearance comes within the specified value. T...Thickness of removed shim A...Measured valve clearance N...Thickness of new shim Intake: N = T + (A - 0.20 mm (0.008 inch)) Exhaust: N = T + (A - 0.30 mm (0.012 inch)) Page 917 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4172 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Diagram Information and Instructions Vehicle Speed Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4719 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 316 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2273 Finding A Short Circuit 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: 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) Voltage Check Page 3726 Ground Points 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. How to Read Power Source Page 3921 5. DISCONNECT BRAKE LINE AND PARKING BRAKE CABLE a. Using SST, disconnect the brake line from the wheel cylinder. SST 09751-36011 Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.) b. 2WD: Remove the 2 bolts and disconnect the parking brake cable. Torque: 9.3 Nm (95 kgf-cm, 82 inch lbs.) 6. REMOVE REAR AXLE SHAFT ASSEMBLY a. Remove the 4 backing plate mounting nuts. Torque: 68 Nm (700 kgf-cm, 50 ft. lbs.) b. Pull out the rear axle shaft assembly from the rear axle housing. NOTICE: Be careful not to damage the oil seal. 7. REMOVE O-RING FROM REAR AXLE HOUSING INSPECTION 1. w/ ABS: REMOVE BEARING RETAINER (DIFFERENTIAL SIDE) AND ABS SPEED SENSOR ROTOR a. Attach 4 nuts to the serration bolts and remove the serration bolts from the backing plate using a hammer. NOTICE: Do not reuse the nuts previously removed from the vehicle. b. Grind the retainer and sensor rotor surfaces using a grinder, then chisel them out with a chisel. c. Attach washers and nuts to the serration bolts, then torque the nuts to install the serration bolts to the backing plate. d. Remove the 4 nuts and washers from the serration bolts. 2. REMOVE SNAP RING FROM AXLE SHAFT Page 3487 Ground Points 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. How to Read Power Source Page 339 Brake Switch (Cruise Control): Electrical Diagrams Page 3792 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3423 Step 1 Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 3819 Page 3493 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1597 Chart 2 Of 2 Page 1918 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 547 Finding A Short Circuit 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: 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) Voltage Check Page 567 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3439 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1457 Page 4581 Load Compensator: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Remove valve bracket. a. Remove the nut, bolt and 2 plate washers. b. 2WD: Remove the 2 nuts and flexible hose bracket, and remove the valve bracket and set plate from the valve body. c. 4WD: Remove the 2 nuts, and remove the valve bracket and set plate from the valve body. Page 458 Finding A Short Circuit 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: 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) Voltage Check Page 1638 Page 3666 Step 3 Page 859 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 4112 Transmission Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 4878 Auxiliary Power Outlet: Electrical Diagrams Service Hints P13, P14 POWER OUTLET 2-GROUND: Approx. 12 Volts with the ignition SW at ACC or ON position 1-GROUND: Always continuity Page 1213 Connecting Rod: Specifications Connecting Rod Nut Connecting Rod Bearing Cap Nuts Step 1 .................................................................................................................................................. ............................... 45 N-m (460 kgf-cm, 33 ft-lbf) Step 2 .................................................................. ................................................................................................................................................. Turn 90° Page 910 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Ford Made System Clutch Switch: Description and Operation Ford Made System 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. Page 2600 CHART 1 Page 2450 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3523 Page 1920 Finding A Short Circuit 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: 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) Voltage Check Page 629 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. 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. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. 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, Os [seconds], 10.2s, 0 and 255). Page 3580 Junction Block and Wire Harness Connector Locations-J/B No.1 Lower Finish Panel (Fig 20) Page 2769 Vehicle Speed Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 2. REMOVE NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Remove the bolt and No.1 vehicle speed sensor assembly. b. Remove the speedometer driven gear and O-ring from the No.1 vehicle speed sensor. 3. INSTALL NO.1 VEHICLE SPEED SENSOR ASSEMBLY a. Coat a new O-ring with ATF. b. Install the O-ring and speedometer driven gear to the No.1 vehicle speed sensor. c. Install the No.1 vehicle speed sensor to the extension housing and torque the bolt. Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.) 4. CONNECT NO.1 VEHICLE SPEED SENSOR CONNECTOR 5. DISCONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR 6. REMOVE NO.2 VEHICLE SPEED SENSOR a. Remove the bolt and No.2 vehicle speed sensor. b. Remove the O-ring from the No.2 vehicle speed sensor. 7. INSTALL NO.2 VEHICLE SPEED SENSOR a. Coat a new O-ring with ATF and install it to the No.2 vehicle speed sensor. b. Install the No.2 vehicle speed sensor and torque the bolt. Page 2320 Ground Points 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. How to Read Power Source Page 2989 Key to Diagrams Power Window Page 2775 Catalytic Converter: Service and Repair REPLACEMENT 1. REMOVE CONVERTER (a) Jack up the vehicle. (b) Check that the converter is cool. (c) Remove the bolts and nuts at the front and rear of the converter. (d) Remove the converter and gasket. 2. REINSTALL CONVERTER (a) Place new gaskets on the converter front and rear pipes and connect the converter the exhaust pipes. (b) Torque the bolts and nuts. Torque: 48 N.m (490 kgf.cm, 35 ft.lbf) Page 1560 Applicable Warranty*: This repair is covered under the 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. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 2192 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Page 1997 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4486 ^ Type "A": Has a projection on the upper and lower side of the brake pad. (See illustration.) ^ 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. 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 3559 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2788 Key to Diagrams Power Window Page 4260 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Service Precautions Fuel Pressure Release: Service Precautions WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 3256 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2093 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3288 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 4594 REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the rubber parts indicated by the arrows. Page 4413 Hydraulic Control Assembly - Antilock Brakes: Description and Operation 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. Fail safe function: If trouble occurs in the ABS solenoid valve circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 1089 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 4435 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 213 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3978 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 656 Page 4582 2. Disconnect spring from valve. Using pliers, remove the clip, and remove the spring from the valve. 3. Remove shackles No.1 and No.2. a. Remove the nut and bolt, and remove the load sensing spring and 2 plate washers. b. Loosen the 2 nuts, and remove the shackle No.1 from the shackle No.2. 4. Disassemble load sensing spring. Disassemble the these parts. 4 bushings. - 2 collars. - 2 rubber plates. - Load sensing valve boot. - Load sensing spring boot. INSPECTION Inspect valve piston pin and load sensing contact surface for wear. Wear limit: 0.7 mm (0.028 inch) REASSEMBLY Page 4438 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4382 Diagnostic Connector - ABS: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2083 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Drivetrain - Revised Rear Axle Oil Seal/Installation Seals and Gaskets: Technical Service Bulletins Drivetrain - Revised Rear Axle Oil Seal/Installation DRIVELINE & DIFFERENTIAL DL002-03 August 6, 2003 Title: REAR AXLE SEAL DESIGN CHANGE Models: '01 - '02 Sequoia, '95 - '02 Tacoma & '00 - '02 Tundra Introduction The rear axle seal lip design has been changed from a flat face type to an angled face type. A different SST seal driver is required to install the seal properly and prevent damaging the oil seal during the installation process. NOTE: Use of SST part number 09951-00610 (Replacer 6-4) as listed in the Repair Manual to install the newly designed rear axle seal can damage the seal assembly causing it to leak. Repair Manual update on Technical Information System (TIS) is in process. Applicable Vehicles ^ 2001 - 2002 model year Sequoia vehicles. ^ 1995 - 2002 model year Tacoma vehicles. ^ 2000 - 2002 model year Tundra vehicles. Parts Information Required SSTs NOTE: Additional SSTs may be ordered by calling SPX/OTC at 1-800-933-8335. Required Tools & Material Warranty Information Identification Procedure Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Exhaust System - Manifold Heat Shield Rattle Noise Heat Shield: Customer Interest Exhaust System - Manifold Heat Shield Rattle Noise Engine EG004-00 June 2, 2000 Title: EXHAUST MANIFOLD HEAT SHIELD RATTLE NOISE Models: '95 - '00 Tacoma Introduction Some Tacoma vehicles may experience a rattle noise caused by the exhaust manifold heat shield. Two wire mesh grommets and a reinforcement patch on the underside have been added to reduce the possibility of the exhaust manifold heat shield rattle noise. Applicable Vehicles ^ 1995 - 2000 model year Tacoma vehicles (except CA Spec.) equipped with 2RZ-FE or 3RZ-FE engines produced before the VINs listed. Production Change Information Parts Information Repair Procedure 1. Inspect the Exhaust Manifold Heat Shield for cracking around the 2 bolts and 2 studs. 2. If cracking is found, replace the Exhaust Manifold Heat Shield, Bolts, Washers, Studs, and Nuts in specified quantities. 3. Insert 2 bolts. (P/N 90110-06894) 4. Reuse studs/nuts in the specified areas. Warranty Information Page 37 Step 2 Step 3 INSPECTION PROCEDURE Page 809 Finding A Short Circuit 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: 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) Voltage Check Page 2787 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3398 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 612 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 2443 Step 2 Step 3 Step 4 Step 5 Page 4101 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1332 TIMING CHAIN AND RELATED COMPONENTS Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Locations Fuse Block: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4227 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1038 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Locations Starter Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4436 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1822 Ground Points 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. How to Read Power Source Page 2005 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1445 Ground Points 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. How to Read Power Source Page 3981 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Technician Safety Information Fuel Tank: Technician Safety Information WARNING: Adhere to the following procedures any time the fuel system is being worked on in order to reduce the risk of fire and personal injury: - Keep a dry chemical (Class B) fire extinguisher near the work area. - Place a "CAUTION FLAMMABLE" sign in the work area. - Work in a well-ventilated area. Do not smoke, and keep sparks and open flames away. - Wear eye protection. - Use caution when working near the catalytic converter to prevent the possibility of burns or fire. (The temperatures within the converter can exceed 537°C (1000°F).) - Relieve the fuel system pressure prior to disconnecting fuel system components. - Disconnect the negative battery cable except for tests where battery voltage is required. - Use a suitable container to store or catch fuel. - Do not replace fuel pipe with fuel hose. - Plug all disconnected fuel line fittings and hoses. - After making any fuel system repairs ALWAYS inspect for fuel leaks. - If available, use system bleed (schrader) valve to relieve fuel system pressure. Page 1307 Intake Manifold: Testing and Inspection For information regarding the testing and inspection of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Disassembly and Reassembly. Page 2659 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4305 Key to Diagrams Power Window Locations Page 4815 Auxiliary Power Outlet: Electrical Diagrams Service Hints P13, P14 POWER OUTLET 2-GROUND: Approx. 12 Volts with the ignition SW at ACC or ON position 1-GROUND: Always continuity Page 4197 Shift Indicator: Testing and Inspection CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. WIRING DIAGRAM Step 1 Page 62 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4781 a. Disconnect the starter connector. b. Remove the nut and disconnect the starter wire. Torque: 8.8 N.m (90 kgf.cm, 78 in.lbf) c. Remove the 2 bolts and starter. Torque: 39 N.m (400 kgf.cm, 29 ft.lbf) INSTALLATION Installation is in the reverse order of removal. Page 4291 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3187 Key to Diagrams Power Window Page 4350 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2168 Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 1805 Diagram Information and Instructions Igniter: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2483 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 822 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 695 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Front Wheel Speed Sensor: Service and Repair Front REMOVAL 1. Remove speed sensor. a. Disconnect the speed sensor connector. b. Remove the 2 (4WD) or 4 (2WD) clamp bolts holding the sensor harness from the steering knuckle, upper arm and side rail. Torque: Upper arm: 8.0 Nm (71 inch lbs.) Side rail: 13 Nm (9 ft. lbs.) c. Remove the speed sensor installation bolt from the steering knuckle. Torque: 8.0 Nm (71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. There are no foreign objects on the sensor or the part of the knuckle to which the sensor is to be installed. - The sensor is installed flat against the knuckle when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. Page 3282 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4232 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 604 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3985 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3207 Ground Points 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. How to Read Power Source Page 2495 Camshaft Position Sensor: Testing and Inspection CAMSHAFT POSITION SENSOR INSPECTION (a) Disconnect the camshaft position sensor connector. (b) Using an ohmmeter, measure the camshaft position sensor resistance between terminals. Resistance: Cold: 835 - 1,400 ohms Hot: 1,060 - 1,645 ohms If the resistance is not as specified, replace the camshaft position sensor. (c) Connect the camshaft position sensor connector. Locations Power Distribution Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Locations Page 1759 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4110 Page 584 Intake Air Temperature Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Specifications Wheel Bearing: Specifications On models with serviceable wheel bearings, use a Lithium Multipurpose Grease. Page 3311 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Specifications Drive Belt: Specifications Drive Belt Tension: New Belt .............................................................................................................................................. .......................................................... 135-180 lbs. Used Belt ............................................................................................................................................. ............................................................. 85-120 lbs. Page 3720 O/D OFF indicator light remains ON Page 1835 Oxygen Sensor: Description and Operation 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 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 in 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 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 temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 3827 4. A340E: REMOVE OIL STRAINER NOTICE: Be careful as some fluid will come out of the oil strainer. a. Separate the solenoid wire. b. Remove the 3 bolts, oil strainer and 2 gaskets. 5. A34OF: REMOVE OIL STRAINER NOTICE: Be careful as some fluid will come out of the oil strainer. a. Remove the 11 bolts, oil strainer from the oil strainer case. b. Remove the 3 gaskets from the oil strainer. c. Remove the 5 bolts and oil strainer case. 6. REMOVE OIL PIPE a. A340E: Pry up both pipe ends with a large screwdriver and remove the 2 pipes. Page 865 Ground Points 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. How to Read Power Source System Diagnosis Air/Fuel Mixture: Testing and Inspection 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 systems, etc. should be properly connected. f. Sequential Multiport Fuel Injection (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 APPROXIMATELY 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. 6. TROUBLESHOOTING If the CO/HC concentration does not comply with regulations, troubleshoot according to the table. a. Check heated oxygen sensor operation. Page 2066 Ignition Cable: Testing and Inspection INSPECT HIGH-TENSION CORDS (a) Remove the air cleaner cap and MAF meter assembly. (b) Remove the intake air connector. (c) Disconnect the high-tension cords from the spark plugs. NOTICE: Pulling on or bending the cords may damage the conductor inside. (d) 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. (e) Using an ohmmeter, measure the resistance. Maximum resistance: 25 k ohms per cord Page 2744 Finding A Short Circuit 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: 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) Voltage Check Page 3252 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 288 Page 2128 Page 622 Applicable Vehicles Page 2614 CHART 21 Page 4793 Starter Relay: Testing and Inspection 1. REMOVE STARTER RELAY LOCATION: The relay is located in the junction block on the driver's side. 2. INSPECT STARTER RELAY CONTINUITY a. 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. 3. INSPECT STARTER RELAY OPERATION a. Apply battery voltage across terminals 1 and 2. b. Using an ohmmeter, check that there is continuity between terminals 3 and 5. If operation is not as specified, replace the relay. 4. REINSTALL STARTER RELAY Page 2444 Step 6 Step 7 INSPECTION PROCEDURE Page 4156 Overdrive Indicator Lamp: Electrical Diagrams Page 4569 2. Disconnect connector. Pull out the release bar, and disconnect the connector. 3. Disconnect brake lines. Using Special Service Tool (SST) 09023-00100 or equivalent, disconnect the 5 brake lines from the ABS actuator. Torque: 15 Nm (11 ft. lbs.) 4. Remove ABS actuator assembly Remove the bolt, 2 nuts and ABS actuator assembly. Torque: 19 Nm (14 ft. lbs.) 5. Remove ABS actuator. Using a T25 torx wrench, remove the 3 bolts and ABS actuator from actuator bracket. Torque: 9 Nm (7 ft. lbs.) INSTALLATION Installation is in the reverse order of removal. After installation, fill brake reservoir with brake fluid, bleed brake system and check for leaks. Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Service and Repair Air Bag(s) Arming and Disarming: Service and Repair 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 of 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 before and adjust the clock. To avoid erasing the memory of each memory system, never use a backup 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, airbag sensor assembly or front airbag sensor directly to hot air or flames. AIR BAG SYSTEM DISARMING The Air Bag/Supplemental Restraint System (SRS) incorporates a backup energy source that maintains sufficient deployment voltage for up to 90 seconds after the ignition is turned Off and the battery has been disconnected. Before disconnecting battery, note radio station settings, since all vehicle memory will be lost. Never use a backup power source from outside the vehicle. 1. Turn ignition to Lock, then disconnect battery ground cable. 2. Wait at least 90 seconds after disconnection before beginning service or diagnostic procedures. AIR BAG SYSTEM ARMING 1. Ensure ignition is in Lock position. 2. Connect battery ground cable. 3. Wait at least 10 seconds before turning ignition from Lock position. 4. Turn ignition to ACC or On position and ensure SRS lamp lights, then goes off after approximately six seconds. If lamp remains lit, an SRS condition is indicated. Refer to Diagnosis and Testing. Page 3950 Page 1867 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1536 Water Pump: Diagrams Page 4086 O/D OFF indicator light remains ON Specifications Idle Speed: Specifications Idle Speed 700 +/- 50 rpm Page 1499 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A," "B " and "C" are not deformed, cracked, or swollen. 3. Check that points "C" and "D" are not stuck together. 4. Apply engine coolant to points "B" and "C" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Specification: If the maximum pressure is less than the minimum standard value, replace the radiator cap sub-assembly. Type: Compact Cap, 88 kPa Page 4698 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1944 Page 3326 Ground Points 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. How to Read Power Source Page 3477 Shift Solenoid: Electrical Diagrams Specifications Camshaft Bearing: Specifications Camshaft Bearing Cap Bolts 15.5 Nm (12 ft.lb) Intake Sequence --Exhaust Sequence --- Page 1654 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Testing and Inspection Catalytic Converter: Testing and Inspection INSPECTION 1. CHECK TWC FOR DENTS OR DAMAGE If any part of the protector is damaged or dented to the extent that it touches the three-way catalytic converter, repair or replace it. 2. CHECK EXHAUST PIPE CONNECTIONS FOR LOOSENESS OR DAMAGE 3. CHECK EXHAUST PIPE CLAMPS FOR WEAKNESS, CRACKS OR DAMAGE 4. CHECK HEAT INSULATOR FOR DAMAGE 5. CHECK FOR ADEQUATE CLEARANCE BETWEEN TWC AND HEAT INSULATOR Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3035 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2613 Page 1448 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 320 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 3070 Page 2627 CHART 29 Page 4018 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1000 b. Check and correct the cause if necessary. Page 4593 4. 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: w/o ABS: 8.0 Nm (69 inch lbs.) w/ ABS: 10 Nm (7 ft. lbs.) 5. Remove 2 pistons and springs. a. 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 possibly that the cylinder bore could be damaged. NOTICE: At the time of disassembly, 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 the distance A) from the rag to the top of the blocks is at least 100 mm (3.94 inch). 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. Page 1245 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 1404 - Select a new shim with a thickness as close as possible to the calculated value. HINT: Shims are available in 17 sized in increments of 0.05 mm (0.0020 inch), from 2.50 mm (0.0984 inch) to 3.30 mm (0.1299 inch). c. Install a new adjusting shim. - Place a new adjusting shim on the valve lifter. Page 3475 Finding A Short Circuit 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: 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) Voltage Check Page 2230 Finding A Short Circuit 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: 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) Voltage Check Locations Relay Box: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 670 Key to Diagrams Power Window Page 2966 Fuel Line Inspection 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. Service and Repair Valve Guide Seal: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 2039 Fuel Pressure: Specifications Volume Specification Information not supplied by the manufacturer. Page 589 Finding A Short Circuit 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: 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) Voltage Check Page 1531 Thermostat: Service and Repair 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. DISCONNECT WATER INLET WITH LOWER RADIATOR HOSE, AND REMOVE THERMOSTAT a. Remove the 2 nuts holding the water inlet to the inlet housing, and disconnect the water inlet from the inlet housing. b. Remove the thermostat. c. Remove the gasket from the thermostat. INSPECTION INSPECT THERMOSTAT HINT: The thermostat is numbered with the valve opening temperature. a. Immerse the thermostat in water and gradually heat the water. Page 4309 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector With Locking Differential Differential Case: Specifications With Locking Differential SERVICE SPECIFICATIONS Differential Case Runout: Maximum ............................................................................................................................................. .................................... 0.07 mm (0.0028 inch) TORQUE SPECIFICATIONS Differential Case To: Ring Gear ............................................................................................................................................ ............................................ 97 Nm (71 ft. lbs.) Differential RH Case To: LH Case ............................................................................................................................................... ........................................... 47 Nm (35 ft. lbs.) Page 3613 Key to Diagrams Power Window Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4898 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 609 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2025 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1218 Crankshaft Main Bearing: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Block Assembly; Service and Repair. Page 2881 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2496 Camshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. REMOVE CAMSHAFT POSITION SENSOR (a) Disconnect the camshaft position sensor connector. (b) Remove the bolts and camshaft position sensor. Torque: 5.4 N.m (55 kgf.cm, 48 in.lbf) INSTALLATION Installation is in the reverse order of removal. Page 1740 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1890 Vehicle Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1088 Fluid - A/T: Fluid Type Specifications A/T Fluid Type ..................................................................................................................................................... .................................. DEXRON II or DEXRON III Page 3259 Finding A Short Circuit 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: 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) Voltage Check Page 2617 CHART 23 Page 673 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Locations Page 2571 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4205 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 4345 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3228 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1904 EGR Temperature Sensor: Testing and Inspection INSPECTION 1. REMOVE EGR VALVE 2. REMOVE EGR GAS TEMPERATURE SENSOR 3. INSPECT EGR GAS TEMPERATURE SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: 64 - 97 K ohms at 50°C (122°F) 11 - 16 K ohms at 100°C (212°F) 2 - 4 K ohms at 150°C (302°F) If the resistance is not as specified, replace the sensor. 4. REINSTALL EGR GAS TEMPERATURE SENSOR 5. REINSTALL EGR VALVE Page 2748 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 451 Position Of Parts In Instrument Panel (2 Of 2) (Fig 31) Page 2425 Ground Points 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. How to Read Power Source Page 3621 Finding A Short Circuit 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: 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) Voltage Check Page 4092 Ground Points 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. How to Read Power Source Page 3554 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 840 Ground Points 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. How to Read Power Source Page 4020 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3969 Flex Plate: Specifications Drive Plate Bolts 74 Nm (54 ft.lb) Page 2865 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Page 2226 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 1154 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1742 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3214 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4652 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2726 Finding A Short Circuit 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: 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) Voltage Check Page 3600 Electronically Controlled Transmission (Part 3 Of 3) Page 89 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 1682 Page 3986 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 536 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2980 (a) When disconnecting the high pressure fuel line, a large amount of gasoline will spill out, so observe these procedures: (1) Put a container under the connection. (2) Slowly loosen the connection. (3) Disconnect the connection. (4) Plug the connection with a rubber plug. (b) When connecting the flare nut or union bolt on the high pressure pipe union, observe these procedures: (1) (Union Bolt Type) Always use a new gasket. (2) (Union Bolt Type) Tighten the union bolt by hand. (3) (Union Bolt Type) Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (4) (Flare Nut Type) Apply a light coat of engine oil to the flare and tighten the flare nut by hand. (5) (Flare Nut Type) Using SST, tighten the flare nut to the specified torque. SST 09631-22020 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). (c) Check that there are no fuel leaks after doing maintenance anywhere on the fuel system. Page 1541 INSPECTION 1. INSPECT WATER PUMP a. Visually check the air hole and 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 FLUID COUPLING a. Remove the 4 nuts and fan from the fluid coupling. b. Check the fluid coupling for damage and silicon oil leakage. If necessary, replace the fluid coupling. c. Install the fan and fluid coupling with the 4 nuts. Torque: 5.5 Nm (55 kgf.cm, 49 inch lbs.) INSTALLATION Installation is in the reverse order of removal. Page 1765 Knock Sensor: Description and Operation 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. Diagram Information and Instructions Shift Indicator: Diagram Information and Instructions Connector Joining Wire Harness and Wire Harness Connector Joining Wire Harness and Wire Harness Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Ground Points Ground Points Page 714 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 718 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 946 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4173 Junction Block and Wire Harness Connector Locations-J/B No.1 Lower Finish Panel (Fig 20) Page 2023 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3038 Key to Diagrams Power Window Page 663 CHART 30 Page 1661 Air Flow Meter/Sensor: Description and Operation 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. Page 4485 E. Apply a small amount of the disc brake caliper grease (1-2 mm thick) to both sides of the 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 flow chart. 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. NOTE: ^ Clean excess grease. from brake pad and caliper. ^ 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: Page 3000 Page 4745 Generator: Mechanical Specifications STD Minimum Slip Ring Diameter 14.2 to 14.4 mm 12.8 mm Brush Exposed Length 9.5 to 11.5 mm 1.5 mm Page 365 Finding A Short Circuit 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: 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) Voltage Check Page 1405 - Using SST (A), press down the valve lifter and remove SST (B). SST 09248-55040 (09248-05410, 09248-05420) d. Recheck the valve clearance. 9. REINSTALL CYLINDER HEAD COVER 10. RECONNECT ENGINE WIRE 11. REINSTALL HIGH-TENSION CORDS TO SPARK PLUGS 12. REINSTALL PCV HOSES 13. REINSTALL INTAKE AIR CONNECTOR Page 1910 Ground Points 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. How to Read Power Source Page 828 Finding A Short Circuit 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: 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) Voltage Check Page 3496 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4358 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Diagram Information and Instructions Overdrive Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3495 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1516 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4884 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3561 Finding A Short Circuit 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: 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) Voltage Check Page 2569 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2965 Fuel Supply Line: Testing and Inspection COMPONENTS CAUTION: - Always use new gaskets when replacing the fuel tank or component parts. - Apply the proper torque to all parts tightened. INSPECTION INSPECT FUEL TANK AND LINE Page 847 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2150 Step 2 Step 3 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. Service and Repair Lifter / Lash Adjuster: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 572 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 846 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3584 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 29) Page 389 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 431 Evaporator Temperature Sensor / Switch: Testing and Inspection On Vehicle Inspections 1. REMOVE GLOVE COMPARTMENT DOOR 2. INSPECT THERMISTOR RESISTANCE a. Disconnect the connector b. Measure resistance between terminals 2 and 5. Standard resistance: 1,500 Ohms at 25 °C (77 °F) If resistance is not as specified, proceed next inspection. Page 28 ABS Main Relay: Description and Operation 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. Fail safe function: If trouble occurs in the ABS relay circuit, the ECU cuts off current to the ABS relay and prohibits ABS control. Page 1785 Page 662 CHART 29 Page 2222 Key to Diagrams Power Window Page 1922 Page 4192 Electronically Controlled Transmission (Part 2 Of 3) Page 3149 Crankshaft Position Sensor: Service and Repair REMOVAL 1. REMOVE ENGINE UNDER COVER 2. REMOVE GENERATOR 3. REMOVE GENERATOR BRACKET Remove the 3 bolts and bracket. Torque: Bolt A: 74.5 N.m (760 kgf.cm, 55 ft.lbf) Bolt B: 18 N.m (180 kgf.cm, 13 ft.lbf) 4. DISCONNECT CRANKSHAFT POSITION SENSOR CONNECTOR 5. REMOVE CRANKSHAFT POSITION SENSOR (a) Remove the 2 bolts and crankshaft position sensor. Torque: 8.5 N.m (85 kgf.cm, 74 in.lbf) (b) Remove the O-ring. HINT: At the time of installation, please refer to the following items. - Always use a new O-ring when installing the crankshaft position sensor. - Apply a light coat of engine oil on the O-ring. INSTALLATION Installation is in the reverse order of removal. Page 2412 Page 1390 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 3781 ^ Torque the bolts to the specification found in the applicable Repair Manual. NOTE In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the torque converter to the flywheel assembly. Page 1514 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3831 b. A340F: Using a plastic hammer, install the pipe into position. NOTICE: Be careful not to bend or damage the pipe. Make sure that the oil pipe or magnet do not interfere with the oil pan. 14. A340E: INSTALL OIL STRAINER a. Install the 2 new gaskets. b. Install the oil strainer with the 3 bolts. Torque: 10 Nm (1100 kgf-cm, 7 ft. lbs.) c. Clamp the solenoid wire. 15. A34OF: INSTALL OIL STRAINER a. Install 2 new gaskets in the oil strainer case. Page 3052 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 399 Cruise Control Switch: Testing and Inspection Denso Made System 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 Step 1 Page 954 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2755 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1952 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3336 Finding A Short Circuit 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: 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) Voltage Check Page 3446 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1566 Applicable Warranty*: This repair is covered under the 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. *Warranty application is limited to correction of a problem based upon a customer's specific complaint. Page 1674 Camshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1912 Key to Diagrams Power Window Page 1347 c. Install the 2 timing chain cover bolts. Torque: 18 Nm (185 kgf.cm,13 ft. lbs.) d. Install the 2 water bypass pipe nuts. Torque: 20 Nm (200 kgf.cm,14 ft. lbs.) e. Remove the cord from the chain. 10. 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 and torque the pulley bolt. SST 09213-54015, 09330-00021 Torque: 260 Nm (2,650 kgf.cm, 193 ft. lbs.) c. w/ A/C: Install the No.3 and No.2 crankshaft pulleys with the 4 bolts. Torque: 25 Nm (250 kgf.cm,18 ft. lbs.) 11. INSTALL OIL STRAINER Install a new gasket and the oil strainer with the bolt and 2 nuts. Torque: 18 Nm (185 kgf.cm,13 ft. lbs.) 12. INSTALL OIL PAN a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the oil pan. - 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. Page 329 Key to Diagrams Power Window Page 4759 4. INSTALL PULLEY a. Install the pulley to the rotor shaft by tightening the pulley nut by hand. b. 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) c. Check that SST (A) is secured to the pulley shaft. d. Mount SST (C) in a vise. e. Install the generator to SST (C). f. To torque the pulley nut, turn SST (A) in the direction shown in the illustration. Torque: 110 N.m (1,125 kgf.cm, 81 ft.lbf) g. Remove the generator from SST (C). h. Turn SST (B), and remove SST (A and B). 5. INSTALL RECTIFIER HOLDER Page 3816 Valve Body: Specifications Tightening Specifications Upper Valve Body X Lower Valve Body ........................................................................................................................... 6.4 Nm (65 kg-cm, 56 inch lbs.) Detent Spring X Valve Body ................................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Oil Strainer X Valve Body ...................................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Valve Body X Transmission Case ........................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Solenoid X Valve Body ........................................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Page 2193 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 4272 Transmission Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 2138 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 580 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Service and Repair Camshaft: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Diagram Information and Instructions Transmission Position Switch/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2663 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4643 Key to Diagrams Power Window Page 2123 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3126 Camshaft Position Sensor: Description and Operation The Camshaft position sensor (G signal) consists of a signal plate and pick up 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 pick up coil change, causing fluctuations in the magnetic field and generating an electromotive force in the pick up 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. Page 2281 Step 2 Step 3 Step 4 Step 5 Page 1456 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 345 Step 2 Step 3 Page 2199 Ground Points 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. How to Read Power Source Page 409 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 545 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Specifications Vacuum Brake Booster: Specifications SERVICE SPECIFICATIONS Booster Push Rod To Piston Clearance: With Special Service Tool (SST) .......................................................................................................................................................... 0 mm (0 inch) TORQUE SPECIFICATIONS Booster Clevis Lock Nut ...................................................................................................................... ................................................ 25 Nm (19 ft. lbs.) Booster To Pedal Bracket ..................................... .......................................................................................................................... 13 Nm (108 inch lbs.) O/D Cancel Signal Circuit Overdrive Switch: Testing and Inspection O/D Cancel Signal Circuit CIRCUIT DESCRIPTION While driving uphill with cruise control activated, in order to minimize gear shifting and provide smooth cruising O/D 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 O/D shifting until these signals are discontinued. WIRING DIAGRAM Page 2594 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. 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. NOTE: ^ "LOW SW V" indicates the O2S voltage when the O2S status changes from rich to lean. ^ "HIGH SW V" indicates the O2S voltage when the O2S status changes from lean to rich. ^ If the O2S voltage is lower than "LOW SW V," the O2S status is lean. ^ If the O2S voltage is higher than "HIGH SW V," the O2S status is rich. 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, Os [seconds], 10.2s, 0 and 255). Page 1870 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 16 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3258 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3005 Step 3 Step 4 Step 5 Step 6 Page 1586 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2349 Applicable Vehicles Locations Headlamp Dimmer Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 1600 Step 6 Step 7 INSPECTION PROCEDURE Engine Controls - A/F And O2 Sensor Identification Oxygen Sensor: Technical Service Bulletins Engine Controls - A/F And O2 Sensor Identification T-SB-0398-09 December 23, 2009 Engine Bank 1 and Bank 2 A/F and 02 Identification Service Category Engine/Hybrid System Section Engine Control Market USA Applicability TSB SUPERSESSION NOTICE The information contained in this TSB supersedes TSB No. EG034-07. ^ Applicability has been updated to include 2009 - 2010 model year vehicles and 2006 - 2010 model year Highlander HV. TSB No. EG034-07 is Obsolete and any printed versions should be discarded. Be sure to review the entire content of this service bulletin before proceeding. Introduction This service bulletin provides information on the proper identification of engine bank 1 and engine bank 2 for correct A/F sensor and oxygen sensor replacement. This bulletin contains information that identifies engine bank 1 and engine bank 2 on the following engines: 1AZ-FE, 2AZ-FE, 2AZ-FE (PZEV), 1GR-FE, 2GR-FE, 2JZ-GE, 1MZ-FE, 3MZ-FE, 1UR-FE, 3UR-FE, 2UZ-FE 5VZ-FE and 1ZZ-FE. ^ Bank 1 (B1) refers to the bank that includes cylinder No. 1. ^ Bank 2 (B2) refers to the bank opposite bank 1. ^ Sensor 1 (S1) refers to the sensor that is located before the catalytic converters. ^ Sensor 2 (S2) refers to the sensor that is located after the catalytic converters. Warranty Information Page 1857 Page 235 Acceleration/Deceleration Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3419 Page 1763 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1358 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check that the battery positive voltage is above 12 volts. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the union bolt and 2 gaskets and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. (d) Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (e) Wipe off any splattered gasoline. (f) Connect the TOYOTA hand-held tester to the DLC3. (g) Turn the ignition switch ON and 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. (k) Reconnect the negative (-) terminal cable to the battery. (l) Turn the ignition switch ON. (m)Measure the fuel pressure. Fuel pressure: Page 4659 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3747 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 3856 Differential Case: Specifications Less Locking Differential SERVICE SPECIFICATIONS Differential Case Runout: Maximum ............................................................................................................................................. .................................... 0.04 mm (0.0016 inch) TORQUE SPECIFICATIONS Differential Case To: Ring Gear ............................................................................................................................................ .......................................... 125 Nm (92 ft. lbs.) Page 4104 Page 3091 Throttle Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Testing and Inspection Hose/Line HVAC: Testing and Inspection 1. INSPECT HOSE AND TUBE CONNECTIONS FOR LOOSENESS 2. INSPECT HOSES AND TUBES FOR LEAKAGE Using a gas leak detector, check for leakage of refrigerant. Page 4077 Overdrive Switch: Description and Operation O/D Main Switch & O/D Off Indicator Light The O/D main switch contacts go open when the switch is pushed in and go closed when it is pushed out. If O/D main switch is at OFF position, the O/D OFF indicator light lights up, and the ECM prohibits shifting overdrive. 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. Page 624 Engine Bank Identification Page 187 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 1626 Ground Points 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. How to Read Power Source Page 1863 Ground Points 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. How to Read Power Source Page 4624 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4533 c. Use compressed air to remove the pistons alternately from the cylinder. CAUTION: Do not place your fingers in front of the pistons when using compressed air. 3. Remove piston seals. Using a screwdriver, remove the 4 seals from the cylinder. INSPECTION 1. Measure pad lining thickness. Using a ruler, measure the pad lining thickness. Standard thickness: 11.5 mm (0.453 inch) Minimum thickness: 1.0 mm (0.039 inch) Replace the pad if the thickness is less than the minimum (the 1.0 mm slit is no longer visible), or if it shows signs of uneven wear. 2. Measure disc thickness. Using a micrometer, measure the disc thickness. Standard thickness: 22.0 mm (0.866 inch) Minimum thickness: 20.0 mm (0.787 inch) If the disc is scored or worn, or if its thickness is less than minimum, repair or replace the disc. 3. Measure disc runout. a. Tighten the disc with the 3 hub nuts. b. Using a dial indicator, measure the disc runout at a position 10 mm (0.39 inch) from the outside edge. Page 2376 CHART 15 Page 2283 Engine Control Module: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO. 2 PANEL 3. REMOVE ECM (a) Disconnect the 4 ECM connectors. (b) Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Locations EFI Main Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 3740 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES With Differential Lock Pinion Gear: Specifications With Differential Lock Drive Pinion Preload At Starting: New Bearing ........................................................................................................................................ ............................. 0.9-1.6 Nm (8.7-13.9 inch lbs.) Reused Bearing ................................................... ................................................................................................................ 0.5-0.8 Nm (4.3-6.9 inch lbs.) Drive Pinion To Ring Gear: Backlash .............................................................................................................................................. ...................... 0.13-0.18 mm (0.0051-0.0071 inch) Page 1290 Engine Oil: Fluid Type Specifications Engine Oil API Classification ................................................................................................... SH Energy Conserving II, SJ Energy Conserving, or ILAC Multigrade Above 0° F (-18°C) .................................. .............................................................................................................................................................. ... 10W-30 All Temperatures ................................................................................................................ .......................................................................................... 5w-30 Page 3664 Overdrive Switch: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 4302 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Power Distribution Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 2437 Engine Control Module: Connector Views Chart 1 Of 2 Page 829 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 634 O2S Application Table O2S Failure Threshold Charts Page 2593 ^ O2S TEST RESULTS A list of the available oxygen sensors will be displayed. 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. * Although this procedure references the Toyota Diagnostic Tester, the O2S test results can be checked using a generic OBD II scantool. Refer to your OBD II scantool operator's manual for specific procedures. Comparing O2S Test Results to Failure Thresholds 1. Determine the correct O2S Failure Threshold Chart for your vehicle by looking in the "O2S Application Table," 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. Example: Page 3570 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 2323 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1854 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1459 Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection INSPECTION 1. DRAIN ENGINE COOLANT 2. REMOVE ECT SENSOR (a) Disconnect the engine wire protector from the 3 brackets. (b) Disconnect the ECT sensor connector. (c) Using a 19 mm deep socket wrench, remove the ECT sensor and gasket. Diagram Information and Instructions Acceleration/Deceleration Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2528 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1639 Igniter: Description and Operation 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 1 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 2 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 power transistors in the igniter cuts off the current to the primary coil in the ignition coil is supplied simultaneously to the two spark plugs via the high-tension cords that are connected to the both ends of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Page 2409 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3799 Diagram Information and Instructions Acceleration/Deceleration Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4765 Ignition Switch: Testing and Inspection INSPECT IGNITION SWITCH CONTINUITY INSPECT KEY UNLOCK WARNING SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 735 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3345 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 1411 Water Pump: Service and Repair Page 3594 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4113 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 2110 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Bench Test Starter Motor: Testing and Inspection Bench Test NOTE: 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. 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. 3. INSPECT CLUTCH PINION GEAR RETURN Disconnect the negative (-) lead from the switch body. Check that the clutch pinion gear returns inward. 4. DO NO-LOAD PERFORMANCE TEST a. Connect the battery and ammeter to the starter as shown. b. Check that the starter rotates smoothly and steadily with the pinion gear moving out. Check that the ammeter shows the specified current. Specified current: 1.4 kW type: 90 A or less at 11.5 V Page 1791 CHART 5 CHART 6 Page 3647 Key to Diagrams Power Window Page 2640 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3629 Step 2 Step 3 INSPECTION PROCEDURE Page 3233 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 495 Key to Diagrams Power Window Page 1972 Ground Points 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. How to Read Power Source Page 1091 Fluid - A/T: Service and Repair 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 2411 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4688 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2466 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Direct Clutch Page 4563 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4146 Key to Diagrams Power Window Page 4362 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3359 Position Of Parts In Engine Compartment (Part 2 Of 2) (Fig 29) Page 3088 Key to Diagrams Power Window Page 4720 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 2641 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1537 WATER PUMP AND RELATED COMPONENTS Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2211 Page 2664 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3705 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2537 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 4030 Shift Indicator: Testing and Inspection CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. WIRING DIAGRAM Step 1 Page 3630 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 3372 Shift Indicator: Connector Views Electronically Controlled Transmission And A/T Indicator-Connectors Electronically Controlled Transmission And A/T Indicator-Connectors Page 2246 Data Link Connector: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1723 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2191 Coolant Temperature Sensor/Switch (For Computer): Description and Operation A thermistor that is built into the engine coolant temperature sensor changes the resistance value according to the engine coolant temperature. The lower the engine coolant temperature sensor, the greater the thermistor resistance value, and the higher the engine coolant temperature sensor temperature, the lower the thermistor resistance value. The engine coolant temperature sensor is connected to the ECM. The 5 V power source voltage in the ECM is applied to the engine coolant temperature sensor from the terminal THA via a resistor R. That is, the resistor R and the engine coolant temperature sensor are connected in series. When the resistance value of the engine coolant temperature sensor changes in accordance with changes in the engine coolant 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 P0115, it operates fail safe function in which the engine coolant temperature is assumed to be 80°C (176°F). Page 722 Transmission Position Switch/Sensor: Description and Operation 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 0 V. 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. 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. 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. Page 1450 Coolant Temperature Sensor/Switch (For Computer): Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2433 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4379 Key to Diagrams Power Window Page 1526 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 3704 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 334 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2969 (7) Turn the ignition switch to LOCK. (8) Disconnect the TOYOTA hand-held tester from the DLC3. Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2746 Page 1701 Finding A Short Circuit 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: 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) Voltage Check Page 2227 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3373 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission (Part 1 Of 3) Page 2893 Page 52 Control Module HVAC: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE AMPLIFIER a. Disconnect the connector from the amplifier. b. Remove amplifier cover. c. Remove the amplifier from the cooling unit. INSTALLATION Installation is in the reverse order of removal. Page 237 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Diagram Information and Instructions Throttle Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 661 CHART 28 Page 3179 Igniter: Description and Operation 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 1 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 2 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 power transistors in the igniter cuts off the current to the primary coil in the ignition coil is supplied simultaneously to the two spark plugs via the high-tension cords that are connected to the both ends of the secondary coil. At the same time, the igniter also sends an ignition confirmation signal (IGF) as a fail-safe measure to the ECM. Page 1363 b. Check and correct the cause if necessary. Page 2792 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3611 Ground Points 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. How to Read Power Source Page 739 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3610 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2308 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. Page 18 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 817 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 4149 Overdrive Indicator Lamp: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4044 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3116 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 407 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3962 SST 09332-25010 e. Using SST, adjust both bearings so that the snap ring grooves are at maximum and equal widths. 7. INSTALL SNAP RING a. Install 2 new snap rings of equal thickness which will allow 0 - 0.05 mm (0 - 0.0020 inch) axial play. HINT: Do not reuse the snap rings. TMC made: DANA made: b. Using a hammer, tap the yoke until there is no clearance between the bearing outer race and snap ring. 8. CHECK SPIDER BEARING Page 234 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3492 Shift Solenoid: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 200 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Page 720 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2660 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2018 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Locations Power Window Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 116 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2724 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2000 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3766 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2200 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 4267 Transmission Position Switch/Sensor: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT 2 OIL COOLER PIPES 2. DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR a. Pry off the lock washer and remove the nut. b. Remove the bolt and pull out the park/neutral position switch. 3. INSTALL AND ADJUST PARK/NEUTRAL POSITION SWITCH 4. CONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR 5. CONNECT 2 OIL COOLER PIPES Page 2298 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1653 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Service and Repair Valve: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 1796 CHART 12 CHART 13 Page 1512 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3344 Step 2 Step 3 INSPECTION PROCEDURE Page 1780 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction 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. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description 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 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required 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 Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 2938 Fuel Injector: Service and Repair REMOVAL 1. REMOVE THROTTLE BODY 2. DISCONNECT ENGINE WIRE (a) Disconnect these connectors: (1) 4 injector connectors (2) Crankshaft position sensor connector (3) Knock sensor connector (4) Camshaft position sensor (b) Disconnect the DLC1 and wire clamp from the brackets. 3. REMOVE DELIVERY PIPE AND INJECTOR (a) Disconnect the vacuum sensing hose from the fuel pressure regulator. (b) Disconnect the fuel return hose from the fuel pressure regulator. (c) Remove the union bolt and 2 gaskets and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. (d) 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. (e) Remove the 4 insulators from the 4 spacers. (f) Pull out the 4 injectors from the delivery pipe. (g) Remove the O-ring and grommet from each injector. INSTALLATION 1. INSTALL INJECTORS TO DELIVERY PIPE Page 1588 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3286 Page 2390 Page 3699 Key to Diagrams Power Window Page 3278 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 618 Testing and Inspection Backup Lamp Switch: Testing and Inspection INSPECT BACK-UP LIGHT SWITCH CONTINUITY If continuity is not as specified, replace the switch. Page 2022 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3700 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4470 Page 3240 Page 552 3. INSPECT ECT SENSOR Using an ohmmeter, measure the resistance between the terminals. Resistance: Refer to the chart graph If the resistance is not as specified, replace the ECT sensor. 4. REINSTALL ECT SENSOR (a) Using a 19 mm deep socket wrench, install the ECT sensor and gasket. Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) (b) Connect the ECT sensor connector. (c) Install the engine wire protector to the 3 brackets. 5. REFILL ENGINE COOLANT Page 4055 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 582 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 173 Page 4348 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Cooling System - Leak at Radiator Overflow Hose Radiator: All Technical Service Bulletins Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 3418 Overdrive Switch: Electrical Diagrams Page 767 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1197 Camshaft Gear/Sprocket: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 393 Finding A Short Circuit 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: 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) Voltage Check Page 1281 Assenmacher Specialty Tools 1-800-525-2943 Locations Page 2460 Key to Diagrams Power Window Page 3061 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4874 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4772 Starter Motor: Testing and Inspection Component Inspection 1. INSPECT 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. 2. INSPECT 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. 3. INSPECT COMMUTATOR FOR DIRTY AND BURNT SURFACES If the surface is dirty or burnt, correct it with sandpaper (No.400) or on a lathe. 4. INSPECT COMMUTATOR CIRCLE RUNOUT a. Place the commutator on V-blocks. b. Using a dial indicator, measure the circle runout. Maximum circle runout: 0.05 mm (0.0020 in.) If the circle runout is greater than the maximum, correct it on a lathe. 5. INSPECT COMMUTATOR DIAMETER Using vernier calipers, measure the commutator diameter. Standard diameter: 1.4 kW type: 30 mm (1.18 in.) Page 4417 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Disconnect connector. 2. Remove ECU a. Using a E5 torx wrench, remove the 4 screws. Torque: 1.8 Nm (16 inch lbs.) 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. REASSEMBLY Reassembly is in the reverse order of disassembly. Page 3199 Knock Sensor: Testing and Inspection INSPECTION 1. REMOVE STARTER 2. REMOVE FUEL FILTER SET BOLTS 3. REMOVE KNOCK SENSOR (a) Disconnect the knock sensor connector. (b) Using SST remove the knock sensor SST 09816-30010 4. INSPECT KNOCK SENSOR Using an ohmmeter, check that there is no continuity between the terminal and body. If there is continuity, replace the sensor. 5. REINSTALL KNOCK SENSOR (a) Using SST, install the knock sensor. SST 09816-30010 Torque: 44 N.m (450 kgf.cm, 33 ft.lbf) (b) Connect the knock sensor connector. 6. REINSTALL FUEL FILTER SET BOLTS Torque: 20 N.m (200 kgf.cm, 14 ft.lbf) 7. REINSTALL STARTER Page 457 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4216 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3657 Overdrive Switch: Electrical Diagrams Page 2473 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 3553 Key to Diagrams Power Window Page 3697 Ground Points 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. How to Read Power Source Page 1847 Key to Diagrams Power Window Page 884 Air Bag Deactivation Switch: Description and Operation Passenger Airbag Cutoff Switch Location Passenger airbag cutoff switch is mounted on the center cluster finish panel. By turning the passenger airbag cutoff switch to OFF with the ignition key, the passenger airbag system can be disabled. Also, in order to notify the passenger that the passenger airbag is disabled, OFF indicator inside the switch will light up. Page 4215 Locations-J/B No.1 Lower Finish Panel (Fig 20) Details Diagram Information and Instructions Vehicle Speed Sensor/Transducer - Cruise Control: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 1420 Coolant: Fluid Type Specifications Using coolant which includes more than 50% ethylene-glycol (but not more than 70%) is recommended. Page 281 Wheel Speed Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2430 Engine Control Module: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1022 If the resistance is greater than the maximum, check the terminals. If necessary, replace the high-tension cord. (f) 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. 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. (g) Connect the high-tension cords to the spark plugs. Secure the high-tension cords with the clamps as shown in the illustration. (h) Install the intake air connector. (i) Install the air cleaner cap and MAF meter assembly. Page 3123 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4024 Shift Indicator: Electrical Diagrams Electronically Controlled Transmission (Part 1 Of 3) Page 413 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4799 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 34) Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 36) Page 4155 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 3337 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 4346 Brake Fluid Pump: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 3193 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3558 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Denso Made System Clutch Switch: Testing and Inspection Denso Made System 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 Step 1 Page 783 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 3095 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3758 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Testing and Inspection EGR Tube: Testing and Inspection REMOVE EGR PIPE Remove the bolt, 4 nuts, EGR pipe and 2 gaskets. HINT: At the time of installation, please refer to the following items. Install 2 new gaskets. Torque: Bolt: 18 N.m (185 kgf.cm, 13 ft.lbf) Nut A: 19 N.m (195 kgf.cm, 14 ft.lbf) Nut B: 20 N.m (200 kgf.cm, 15 ft.lbf) Page 1344 NOTICE: Check that No.1 cylinder is at TDC and that the weights of the No.1 and No.2 balance shafts are at the bottom side. 1. INSTALL NO.4 VIBRATION DAMPER Install the No.4 damper with the 2 bolts. 2. INSTALL NO.2 TIMING CHAIN, NO.2 CRANKSHAFT TIMING SPROCKET, BALANCE SHAFT DRIVE GEAR AND SHAFT a. Install the No.2 timing chain by matching its mark links with the timing marks on the No.2 crankshaft timing sprocket and balance shaft timing sprocket. b. Fit the other mark link of No.2 timing chain onto the sprocket behind the large timing mark of the balance shaft drive gear. c. Insert the balance shaft drive gear shaft through the balance shaft drive gear so that it fits into the thrust plate hole. Then align the small timing mark of the balance shaft drive gear with the timing mark of the balance shaft timing gear. d. Install the bolt to the balance shaft drive gear and tighten it. Torque: 25 Nm (250 kgf.cm, 18 ft. lbs.) e. Check that each timing mark is matched with the corresponding mark link. 3. INSTALL NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER NOTICE: Assemble the chain tensioner with the pin installed, then remove the pin after assembly. When doing this, avoid pushing the No.2 vibration damper against the chain. a. Install the No.2 chain tensioner with the nut. Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.) b. Install No.3 damper with the 2 bolts. Torque: 18 Nm (185 kgf.cm, 13 ft. lbs.) Page 4809 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 509 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP Page 2185 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4746 Page 2563 Ground Points 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. How to Read Power Source Page 948 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3490 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4073 Finding A Short Circuit 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: 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) Voltage Check Page 1754 Key to Diagrams Power Window Page 2703 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 579 Ground Points 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. How to Read Power Source Page 4603 Parking Brake Lever: Testing and Inspection ON-VEHICLE INSPECTION 1. Check 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 (44.1 lbs.): 12-1 8 clicks 2. 2WD: If necessary, adjust parking brake. HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. a. Tighten the adjusting nut until the travel is correct. Then tighten the lock nut. b. After adjusting the parking brake, confirm that the rear brakes are not dragging. 3. 4WD: If necessary, adjust parking brake. HINT: Before adjusting the parking brake, make sure that the rear brake shoe clearance has been adjusted. a. Tighten 1 of the adjusting nuts of the intermediate lever while loosening the other one until the travel is correct. Tighten the 2 adjusting nuts. b. After adjusting the parking brake, confirm that the bellcrank stopper screw comes into contact with the backing plate. Page 1628 Key to Diagrams Power Window Page 1090 Fluid - A/T: Testing and Inspection 1. Operate vehicle, allow transmission fluid temperature to reach 158-176 °F. 2. Position vehicle on level surface, apply parking brake. 3. Allow engine to idle, depress brake pedal, then move shift lever through all positions. 4. Remove transaxle dipstick, wipe clean, then replace. 5. Remove again, then check fluid level in HOT range. NOTICE: Do not overfill. (a) Check the fluid condition. If the fluid smells burnt or is black, replace it. (b) Replace the ATF. (1) Remove the drain plug and drain the fluid. (2) Reinstall the drain plug securely. 7. On A340D units: Dry capacity is 6.9 US quarts. Drain and Refill: 2.4 Liters (2.5 US qts, 2.1 Imp. qts.) 8. On A340E units: Dry capacity is 7.6 US quarts. Drain and Refill: 1.6 Liters (1.7 US qts, 1.4 Imp. qts.) 9. On A340F units: Dry capacity 1996 9.3 US quarts. Dry capacity 1997-99 10.7 US quarts. Drain and Refill: 2.0 Liters (2.1 US qts, 1.8 Imp. qts.) 10. On A340H units, dry capacity for transaxle and transfer is 10.9 US quarts. Page 3488 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2146 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Diagram Information and Instructions Shift Solenoid: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4508 Brake Drum: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Drum Brake System; Service and Repair. Page 1942 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 1331 Page 1242 a. Check only the valves indicated. - Using a thickness gauge, measure the clearance between the valve lifter and camshaft. - Record the out-of-specification valve clearance measurements. They will be used later to determine the required replacement adjusting shim. Valve clearance (Cold): Intake: 0.15 - 0.25 mm (0.006 - 0.010 inch) Exhaust: 0.25 - 0.35 mm (0.010 - 0.014 inch) b. Turn the crankshaft pulley 1 revolution (360°) and align its groove with timing mark "O" of the timing chain cover. c. Check only the valves indicated as shown. Measure the valve clearance. (See procedure in step (a)) 8. ADJUST VALVE CLEARANCE a. Remove the adjusting shim. - Turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. - Position the notch of the valve lifter toward the spark plug side. - Using Special Service Tool (SST) (A), press down the valve lifter and place (SST) (B) between the camshaft and valve lifter flange. Remove SST (A). SST 09248-55040 (09248-05410, 09248-05420) HINT: ^ Apply SST (B) at slight angle on the side marked with "9", at the position shown in the illustration. Page 4524 5. IF NECESSARY, CHECK VALVE BODY (a) Assemble the valve body in the uppermost position. HINT: When the brakes are applied, the position will move down about 0.8 mm (0.03 in.). Even at this time, the piston should not make contact with or move the load sensing spring. (b) In this position, check the rear brake pressure. if the measured value is not within the standard, replace the valve body. Locations Actuator Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4703 Wheel Speed Sensor: Service and Repair Rear REMOVAL 1. Remove speed sensor. a. Disconnect the speed sensor connector, and pull out the sensor wire harness with grommet. b. Remove the 5 resin clips, 2 clamp set bolts and 2 nuts holding the sensor wire harness from the side rail, fuel tank and axle housing. Torque: 13 Nm (9 ft. lbs.) c. Remove the 2 mounting bolts and speed sensor. Torque: 8.0 Nm (71 inch lbs.) NOTICE: At the time of installation, please refer to the following items. There are no objects on the sensor or the part of the axle end to which the sensor is to be installed. - The sensor is installed flat against the axle end when you tighten the bolt. - When installing the resin clips, use new ones. INSTALLATION Installation is in the reverse order of removal. After installation, check speed sensor signal. Page 3736 Finding A Short Circuit 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: 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) Voltage Check Page 3486 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1500 1. Remove coolant and any foreign material on rubber points "A," "B," and "C." 2. Check that points "A" and "B" are not deformed, cracked, or swollen. 3. Check that points "B" and "C" are not stuck together. 4. Apply engine coolant to point "B" before using the radiator cap tester. ^ Radiator Cap Tester: Snap-On/Sun P/N SVTS262A (or equivalent) 5. Before installing the radiator cap tester, use the applicable radiator cap adaptor provided in the following SST kits in conjunction with the radiator cap tester: ^ SST P/N 09230-00030-01 (09231-10080-01) or 09230-00020-01 (09231-10060-01) or 09230-00050-01(09231-10110-01 6. When using the radiator cap tester, tilt it more than 30 degrees. 7. Pump the radiator cap tester several times, and check the maximum pressure. Pumping speed: 1 pump/second HINT: Stop pumping when the valve opens and read the gauge. The gauge must be within the standard values listed below when the pressure valve opens. The cap is considered OK when the pressure holds steady or falls very slowly, but holds within the standard values listed below for one minute. Page 4495 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. 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 3672 7. INSTALL PARKING LOCK PAWL BRACKET Torque: 7.4 Nm (75 kgf-cm, 65 inch lbs.) HINT: Push the lock rod fully forward. - Check that the parking lock pawl operates smoothly. 8. INSTALL VALVE BODY Page 4534 Maximum disc runout: 0.07 mm (0.0028 inch) If the runout is greater than maximum, replace the disc or grind it on a "On-Car" brake lathe. HINT: Before measuring the runout, confirm that the front bearing play is within specification. 4. If necessary, adjust disc runout. a. Remove the hub nuts and disc. Reinstall the disc 1/6 of a turn round 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. b. Repeat a) until the disc has been installed on the 4 remaining hub position. c. If the minimum runout recorded in a) and b) is less than maximum disc runout, install the disc in that position. d. If the minimum runout recorded in a) and b) is greater than maximum disc runout, replace the disc and repeat step 3. REASSEMBLY Reassembly is in the reverse order of disassembly. NOTICE: Apply lithium soap base glycol grease to the parts indicated by the arrows. Page 2019 Ground Points 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. How to Read Power Source Page 4691 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 2393 CHART 28 Page 952 Transmission Position Switch/Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4378 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2178 Ground Points 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. How to Read Power Source Page 176 Air Bag Control Module: Testing and Inspection INSPECTION 1. VEHICLES NOT INVOLVED IN A COLLISION Do a diagnostic System check. 2. VEHICLES INVOLVED IN A COLLISION AND SRS IS NOT DEPLOYED Do a diagnostic system check. 3. VEHICLES INVOLVED IN A COLLISION AND SRS IS DEPLOYED Replace the airbag sensor assembly. REPLACEMENT REQUIREMENT 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. Page 2924 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 694 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3574 O/D OFF indicator light remains ON Page 362 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 1961 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Locations Shift Interlock Relay: Locations Locations-R/B No.2-Engine Compartment Left (Fig 19) Page 4193 Electronically Controlled Transmission (Part 3 Of 3) Page 3294 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 4487 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. 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 3098 Page 2490 Finding A Short Circuit 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: 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) Voltage Check Page 21 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 4019 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2344 Malfunction Indicator Lamp: Testing and Inspection MALFUNCTION INDICATOR LAMP (MIL) CHECK 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. 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. Page 2126 Finding A Short Circuit 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: 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) Voltage Check Page 674 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2354 Applicable Vehicles Page 2301 With Differential Lock Companion Flange: Specifications With Differential Lock SERVICE SPECIFICATIONS Vertical Runout: Maximum ............................................................................................................................................. .................................... 0.10 mm (0.0039 inch) Horizontal Lateral Runout: Maximum ............................................................................................................................................. .................................... 0.10 mm (0.0039 inch) TORQUE SPECIFICATIONS Companion Flange To Drive Pinion: Standard .............................................................................................................................................. ........................................ 196 Nm (145 ft. lbs.) Maximum .................................................................. .................................................................................................................. 343 Nm (253 ft. lbs.) Page 2247 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2001 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 3051 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 3908 a. Using a chisel and hammer, loosen the staked part of the nut. b. Using SST to hold the flange, remove the nut. SST 09330-00021 c. Using SST, remove the companion flange. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020, 09956-03050) 4. REMOVE OIL SEAL Using SST, remove the oil seal. SST 09350-32014 (09308-10010) 5. Except 3RZ-FE, 5VZ-FE w/o Diff. lock: REMOVE OIL SLINGER 6. REMOVE FRONT BEARING Using SST, remove the front bearing from the drive pinion. SST 09556-22010 Page 672 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 4284 Key to Diagrams Power Window Page 3954 1. 3-joint type: SEPARATE PROPELLER SHAFT AND INTERMEDIATE SHAFT a. Place matchmarks on the flanges. b. Remove the 4 nuts, bolts and washers. c. Separate the propeller shaft and intermediate shaft. 2. 3-joint type: REMOVE FLANGE FROM INTERMEDIATE SHAFT a. Using a chisel and hammer, loosen the staked part of the nut. b. Using SST to hold the flange, remove the nut and spacer. SST 09330-00021 c. Place matchmarks on the flange and shaft. d. Using SST, remove the flange from the intermediate shaft. SST 09950-30011 (09951-03010, 09953-03010, 09954-03010, 09955-03030, 09956-03020) e. Remove the spacer. 3. 3-joint type: REMOVE CENTER SUPPORT BEARING FROM INTERMEDIATE SHAFT 4. REMOVE SLEEVE YOKE FROM PROPELLER SHAFT a. Place matchmarks on the sleeve yoke and shaft. b. Pull out the sleeve yoke from the shaft. c. Remove the dust cover from the shaft. INSPECTION NOTICE: Be careful not to grip the propeller shaft tube too tightly in a vise as this will cause deformation. Page 1681 Page 1746 Intake Air Temperature Sensor: Description and Operation 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. Figure 1 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. 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 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. Page 1886 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 417 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2177 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Cooling System - Leak at Radiator Overflow Hose Coolant Reservoir: All Technical Service Bulletins Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 3307 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 638 CHART 7 Page 4687 Ground Points 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. How to Read Power Source Page 4380 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3334 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 248 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3904 Ring Gear: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Differential; Service and Repair. Page 266 Repair Procedure 1. Disconnect the cable from the negative (-) battery terminal for MORE THAN two (2) seconds. 2. Reconnect the cable to the negative (-) battery terminal. 3. Perform the applicable zero point calibration of the yaw rate sensor and/or the steering angle sensor. HINT Refer to the applicable TSB or Repair Manual for the zero point calibration procedure. 4. Re-initialize all applicable systems available on the vehicle (power window sunroof power lift door etc.). Page 1010 Torque: 30 N.m (310 kgf.cm, 22 ft.lbf) Page 462 Key Reminder Switch: Description and Operation Current always flows to TERMINAL 12 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 6 of the integration relay. At the same time, current flows to TERMINAL A-2 of the relay from the GAUGE fuse through the Seat Belt Warning Light. This current activates the integration relay and, for Approx. 4-8 Seconds, current flowing through the warning light flows from TERMINAL A-2 of relay to TERMINAL A-7 to GROUND, causing the warning Light to Light up. At the same time as the warning Light Lights up, a buckle SW ON signal is input to TERMINAL A-3 of the integration relay, the current flowing from TERMINAL 12 of the relay flows to TERMINAL A-7 to GROUND and the Seat Belt Warning Buzzer Sounds for Approx. 4-8 Seconds. However, if the Seat Belt is put ON (Buckle SW OFF) during this period (While The Buzzer Is Sounding), signal input to TERMINAL A-3 of the integration relay Stops and the current flowing from TERMINAL 12 of the integration relay to TERMINAL A-7 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 front LH door open (Door Courtesy SW ON), when a signal is input to TERMINAL A-10 of the integration relay, the Integration Relay operates, current flows from TERMINAL 6 of the relay to TERMINAL A-7 to GROUND and the Key Reminder Buzzer Sounds. Page 2383 Page 4163 Overdrive Indicator Lamp: Testing and Inspection O/D Main Switch & O/D Off Indicator 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 O/D. WIRING DIAGRAM INSPECTION PROCEDURE Page 2510 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 759 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 2040 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check that the battery positive voltage is above 12 volts. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the union bolt and 2 gaskets and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. (d) Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (e) Wipe off any splattered gasoline. (f) Connect the TOYOTA hand-held tester to the DLC3. (g) Turn the ignition switch ON and 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. (k) Reconnect the negative (-) terminal cable to the battery. (l) Turn the ignition switch ON. (m)Measure the fuel pressure. Fuel pressure: Page 2282 Step 6 Step 7 INSPECTION PROCEDURE Page 17 Key to Diagrams Power Window Page 3122 Finding A Short Circuit 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: 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) Voltage Check Page 4699 Page 3327 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2436 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2300 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2309 Idle Speed/Throttle Actuator - Electronic: Component Tests and General Diagnostics Component Inspection INSPECTION 1. 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). Using an ohmmeter, measure the resistance between terminal +B and other terminals (RSC, RSO). Resistance: Cold: 17.0 - 24.5 ohms Hot: 21.5 - 28.5 ohms If resistance is not as specified, replace the IAC valve. 2. 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. (b) Connect the positive (+) lead from the battery to terminal +B and negative (-) lead to terminal RSO and check that the valve is open. On-Vehicle Inspection ON-VEHICLE INSPECTION INSPECT IAC VALVE OPERATION (a) initial conditions: - Engine at normal operating temperature - idle speed check correctly Page 4786 c. Temporarily tighten the terminal nuts. 5. TIGHTEN TERMINAL NUT a. 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) NOTE: 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: 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. b. Using SST, tighten the nuts to the specified torque. SST 09810-38140 Torque: 17 N.m (170 kgf.cm, 12 ft.lbf) NOTE: If the nut is over tightened, it may cause cracks on the inside of the insulator. Page 561 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2158 Key to Diagrams Power Window Page 3794 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 4255 Key to Diagrams Power Window Capacity Specifications Fluid - M/T: Capacity Specifications M/T Fluid .............................................................................................................................................. ............................................................ 2.6L (2.7 Qt) Page 3533 Fluid - A/T: Service Precautions DO NOT over fill transmission beyond normal fluid level markings. Fluid foaming and transmission damage may occur. Page 3094 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 454 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2800 Vapor Pressure Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) 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 - 3.6V (3) Apply pressure (1.5 kPa, 15 kgf/sq.cm, 0.2 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 3273 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 988 Alignment: Tools and Equipment Equipment Tire pressure gauge Dial indicator with magnetic base Wheel balancer Page 1924 Vapor Pressure Sensor: Testing and Inspection INSPECTION 1. INSPECT POWER SOURCE VOLTAGE OF VAPOR PRESSURE SENSOR (a) Disconnect the vapor pressure sensor connector. (b) Turn the ignition switch ON. (c) Using a voltmeter, measure the voltage between connector terminals VC and E2 of the wiring harness side. Voltage: 4.5 - 5.5V (d) Turn the ignition switch to LOCK. (e) Reconnect the vapor pressure sensor connector. 2. INSPECT POWER OUTPUT OF VAPOR PRESSURE SENSOR (a) Turn the ignition switch ON. (b) Disconnect the vacuum hose from the vapor pressure sensor. (c) 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 - 3.6V (3) Apply pressure (1.5 kPa, 15 kgf/sq.cm, 0.2 psi) to the vapor pressure sensor. Voltage: 4.2 - 4.8V (d) Reconnect the vacuum hose to the vapor pressure sensor. Page 690 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1893 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4386 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2508 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2582 Applicable Vehicles Page 676 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2233 Crankshaft Position Sensor: Description and Operation 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 G signals, and the actual crankshaft angle and the engine speed by the NE signals. Page 3158 Ignition Coil: Testing and Inspection INSPECT IGNITION COIL (a) Disconnect the high-tension cords from the ignition coil. (b) Disconnect the ignition coil connectors. (c) Using an ohmmeter, measure the secondary coil resistance between the positive (+) and high-tension terminals. Secondary coil resistance: Cold: 9.7 - 16.7 k ohms Hot: 12.4 - 19.6 k ohms If the resistance is not as specified, replace the ignition coil. (d) Connect ignition coil connectors. (e) Connect the high-tension cords from the ignition coils. Page 4405 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 2103 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 229 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2139 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1954 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 3871 Drain Plug: Specifications Less Locking Differential Drain Plug ............................................................................................................................................ ..................................................... 49 Nm (36 ft. lbs.) Service and Repair Throttle Valve Cable/Linkage: Service and Repair ON-VEHICLE REPAIR 1 DISCONNECT THROTTLE CABLE a. Disconnect the cable from the throttle linkage. b. Disconnect the cable from the cable clamps in the engine compartment. c. Remove the bolt and disconnect the cable clamp from the torque converter clutch housing. 2. REMOVE VALVE BODY 3. REMOVE THROTTLE CABLE Remove the retaining bolt and pull out the throttle cable. 4. INSTALL THROTTLE CABLE a. Be sure to push it in all the way. b. Install the bolt. 5. INSTALL VALVE BODY 6. IF THROTTLE CABLE IS NEW, STAKE STOPPER ON INNER CABLE HINT: New cable does not have a staked cable stopper. a. Bend the cable so there is a radius of about 200 mm (7.87 inch). 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 inch) from the end of outer cable. 7. CONNECT THROTTLE CABLE a. Install the bolt and connect the cable clamp to the torque converter clutch housing. b. Connect the cable to the cable clamps in the engine compartment. c. Connect the cable to the throttle linkage. 8. ADJUST THROTTLE CABLE 9. FILL TRANSMISSION WITH ATF Page 2275 Engine Control Module: Connector Views Chart 1 Of 2 Page 1520 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 2791 Vapor Pressure Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 995 Fuel Pressure: Testing and Inspection FUEL PRESSURE INSPECTION CHECK FUEL PRESSURE (a) Check that the battery positive voltage is above 12 volts. (b) Disconnect the negative (-) terminal cable from the battery. (c) Remove the union bolt and 2 gaskets and disconnect the fuel inlet pipe from the delivery pipe. HINT: Put a suitable container or shop rag under the delivery pipe. - Slowly loosen the union bolt. (d) Install the fuel inlet pipe and SST (pressure gauge) to the delivery pipe with the 3 gaskets and SST (union bolt). SST 09268-45012 Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (e) Wipe off any splattered gasoline. (f) Connect the TOYOTA hand-held tester to the DLC3. (g) Turn the ignition switch ON and 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. (k) Reconnect the negative (-) terminal cable to the battery. (l) Turn the ignition switch ON. (m)Measure the fuel pressure. Fuel pressure: Page 1934 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4274 Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.) 8. CONNECT NO.2 VEHICLE SPEED SENSOR CONNECTOR Page 1813 CHART 27 Page 1662 Air Flow Meter/Sensor: Testing and Inspection INSPECTION Terminal Identification Reference 1. INSPECT MAF METER RESISTANCE Using an ohmmeter, measure the resistance between terminals THA and E3. If the resistance is not as specified, replace the MAF meter. 2. INSPECT MAF METER OPERATION (a) Connect the negative (-) terminal cable to the battery. (b) Turn the ignition switch ON. (c) Connect the MAF meter connector. (d) Using a voltmeter, connect the positive (+) tester probe to terminal VG and negative (-) tester probe to terminal E3. (e) Blow air into the MAF meter and check that the voltage fluctuates. If operation is not as specified, replace the MAF meter. (f) Turn the ignition switch LOCK. (g) Disconnect the negative (-) terminal cable from the battery. (h) Disconnect the MAF meter connector. Page 4668 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 4523 Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 1135 Rear brake pressure HINT The brake pedal should not be depressed twice and/or returned while setting to the specified pressure. Read the value of rear brake pressure 2 seconds after adjusting the specified fluid pressure. If the brake pressure is incorrect adjust the fluid pressure. 4. IF NECESSARY, ADJUST FLUID PRESSURE (a) Adjust the length of the No.2 shackle. Low pressure - Lengthen A High pressure - Shorten A Initial set Adjustment range HINT: One turn of the nut changes the fluid pressure as shown in the following table. Rear brake pressure: (b) If the pressure cannot be adjusted by the No.2 shackle, raise or lower the valve body. Low pressure - Lower body High pressure - Raise body (c) Torque the nuts. Torque: 13 N.m (130 kgf.cm, 9 ft.lbf) (d) Adjust the length of the No.1 shackle again. If it cannot be adjusted, inspect the valve housing. Page 1069 6. INSPECT AIR CONDITIONING OPERATION Page 2912 D. Start the engine. After the engine has stalled, turn the ignition switch OFF. E. Disable the fuel return line by blocking the line or installing the appropriate plug in the return outlet, if applicable. NOTE: Do NOT clamp plastic lines. F. Install the device adapter to the fuel line and then secure the swivel fitting on the end of the hose. G. Make sure the ball valve on the device is turned OFF (valve handle is crosswise to device). Screw the can of EFI cleaner (P/N 00289-1PF14) onto the device can adapter. H. Open the valve on the device, start the vehicle, and allow it to run until the engine stalls. I. Turn the ball valve OFF and remove the empty can. J. Place a shop towel over the can adapter and slowly open the ball valve to depressurize the system. K. Remove supply and return line adapters, reconnect vehicle fuel supply and return lines (replacing any fuel line gaskets and seals), and connect the fuel pump electrical connector. L. Before starting the vehicle, pressurize the fuel system and check for leaks. Run the engine for 4 - 5 minutes, and then snap the throttle several times to dislodge any carbon that may remain in the system. 2. Add 1 can of Toyota Non-Pressurized Fuel Injector Cleaner Fuel Tank Additive (P/N 08813-0080DS) to the fuel tank. 3. Road test the vehicle to verify normal operation. Page 2619 CHART 24 Page 3287 Knock Sensor: Description and Operation 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. Page 15 Ground Points 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. How to Read Power Source Diagram Information and Instructions Braking Sensor/Switch: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3304 Ground Points 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. How to Read Power Source A/T.P. (Automatic Transmission Parking) Indicator Circuit Shift Indicator: Description and Operation A/T.P. (Automatic Transmission Parking) Indicator Circuit CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. Page 2795 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4836 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 3883 Pinion Bearing: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Differential; Service and Repair. Page 2190 Page 3076 Reference (c) Using an ohmmeter, measure the resistance between each terminal. (d) Reconnect the sensor connector. 3. INSPECT THROTTLE OPENER (a) Allow the engine to warm up to normal operating temperature. (b) Check the idle speed. Idle speed: 650 - 750 rpm (c) Disconnect the vacuum hose from the throttle opener and plug the hose end. (d) Check the throttle opener setting speed. Throttle opener setting speed: 1,200 - 1,500 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. (h) Disconnect TOYOTA hand-held tester or OBD II scan tool. Page 2072 Spark Plug: Specifications Torque Specification Spark Plug x Cylinder Head ................................................................................................................ ......................................................................... 20 Nm Page 588 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 1627 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1102 Fluid - Differential: Service Precautions DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur. Page 3473 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 3134 Ground Points 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. How to Read Power Source Page 2413 Oxygen Sensor: Description and Operation 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 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 in 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 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 temp. of the exhaust gas is low) current flows to the heater to heat the sensor for accurate oxygen concentration detection. Page 2610 CHART 16 CHART 17 Page 2358 Oxygen Sensor: Technical Service Bulletins Engine Controls - O2 Sensor Monitor Threshold Values SPECIAL SERVICE TOOLS SS002-03 December 17, 2003 Title O2S TEST RESULTS (MODE 05) Models All '96 - '03, '04 Corolla, ECHO, Matrix, Sienna & Scion xA & xB Introduction 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. Applicable Vehicles ^ All 1996 - 2003 model year Toyota vehicles. ^ 2004 model year Corolla, ECHO, Matrix and Sienna vehicles. ^ 2004 model year Scion xA and xB vehicles. Function Description 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 02S test results is described in the following three basic steps: 1. Completing the O2S Readiness Monitor. 2. Accessing O2S Test Results. 3. Comparing O2S Test Results to Failure Thresholds. Required 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 Completing O2S Readiness Monitor 1. Clear any stored Diagnostic Trouble Codes (DTCs) using the Toyota Diagnostic Tester. Page 741 Finding A Short Circuit 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: 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) Voltage Check Page 387 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3709 Overdrive Switch: Electrical Diagrams Page 4555 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1359 265 - 304 kPa (2.7 - 3.1 kgf/sq.cm, 38 - 44 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 - Injectors (n) Remove the TOYOTA hand-held tester. (o) Start the engine. (p) Measure the fuel pressure at idle. Fuel pressure: 206 - 255 kPa (2.1 - 2.6 kgf/sq.cm, 31 - 37 psi) If pressure is not as specified, check the vacuum sensing hose and fuel pressure regulator. (q) Stop the engine. (r) Check that the fuel pressure remains as specified for 5 minutes after the engine has stopped. Fuel pressure: 147 kPa (1.5 kgf/sq.cm, 21 psi) or more If pressure is not as specified, check the fuel pump, pressure regulator and/or injector. (s) After checking fuel pressure, disconnect the negative (-) terminal cable from the battery and carefully remove the SST to prevent gasoline from splashing. SST 09268-45012 (t) Reconnect the fuel inlet pipe to the delivery pipe with 2 new gaskets and the union bolt. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) (u) Reconnect the negative (-) terminal cable to the battery. (v) Check for fuel leakage. Page 3524 Page 3277 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 277 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2219 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Cooling System - Leak at Radiator Overflow Hose Coolant Reservoir: Customer Interest Cooling System - Leak at Radiator Overflow Hose ENGINE EG012-99 November 5, 1999 Title: RADIATOR LEAK FROM OVERFLOW PIPE Models: '98 - '99 Tacoma Introduction Due to a casting mismatch, some 1998 - 1999 Tacomas may experience a leak from the coolant overflow pipe hose where it connects to the radiator upper tank. Affected Vehicles ^ 1998 - 1999 model year Tacoma produced between the VINs specified as shown. Parts Information Repair Procedure 1. Remove the overflow hose from the overflow pipe. 2. Using 240 grit sandpaper, smooth the outer surface of the overflow pipe on the upper radiator tank as shown. 3. Repeat using 400 grit sandpaper. 4. Reinstall hose utilizing the field fix Clip. NOTE: Do not use a knife for this procedure and do not sand in a horizontal direction. Warranty Information Page 2364 Page 3796 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 597 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points A/T, M/T - Alignment Pin Service Precaution Continuously Variable Transmission/Transaxle: Technical Service Bulletins A/T, M/T - Alignment Pin Service Precaution T-SB-0053-08 May 8, 2008 Alignment Pin Installation during Transmission/Transaxle Assembly Installation Service Category Drivetrain Section Automatic Transmission/Transaxle Market USA Applicability Introduction The purpose of this TSB is to provide information regarding the installation of alignment pins during transmission/transaxle assembly installation. Missing alignment pins may result in incorrect alignment and failure of the transmission/transaxle assembly. Use the information below when installing a transmission/transaxle assembly. Parts Information Warranty Information Repair Procedure 1. Inspect the rear side of the engine block assembly for 2 alignment pins. ^ If there are less than 2 alignment pins present one may have been removed with the transmission/transaxle assembly. Check the removed assembly for the missing alignment pins. Go to step 2. Page 1326 Camshaft Gear/Sprocket: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 4233 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3424 Step 2 Step 3 INSPECTION PROCEDURE Page 493 Ground Points 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. How to Read Power Source Page 2583 Page 3472 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 346 Step 4 INSPECTION PROCEDURE Page 610 Page 2484 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1601 Engine Control Module: Service and Repair REMOVAL 1. REMOVE GLOVE COMPARTMENT DOOR 2. REMOVE LOWER FINISH NO. 2 PANEL 3. REMOVE ECM (a) Disconnect the 4 ECM connectors. (b) Remove the 2 bolts and ECM. INSTALLATION Installation is in the reverse order of removal. Page 1256 Valve Cover: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair. Page 1490 3. DISCONNECT AIR PIPE Remove the 2 bolts and disconnect the air pipe. 4. DISCONNECT UPPER RADIATOR HOSE 5. DISCONNECT RADIATOR RESERVOIR HOSE 6. DISCONNECT LOWER RADIATOR HOSE 7. REMOVE NO.2 FAN SHROUD 8. A/T: DISCONNECT OIL COOLER HOSES 9. REMOVE RADIATOR Remove the 4 bolts and radiator. Torque: 12.5 Nm (125 kgf.cm, 9 ft. lbs.) HINT: At the time of installation, please refer to the following items. Insert the tabs of the radiator support through the radiator service holes. DISASSEMBLY 1. REMOVE NO.1 FAN SHROUD Remove the 4 bolts and fan shroud. Page 4402 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 3968 ^ Torque the bolts to the specification found in the applicable Repair Manual. NOTE In most applications there will be 1 black torque converter bolt, be sure to install this bolt first to aid in aligning the torque converter to the flywheel assembly. Specifications Wheel Speed Sensor: Specifications Speed Sensor Installation Bolt 71 in.lb Front Speed Sensor Harness To: Upper Arm 71 in.lb Side Rail 108 in.lb Rear Speed Sensor Harness To: Axle Housing 108 in.lb Fuel Tank 108 in.lb Side Rail 108 in.lb Page 4592 Brake Master Cylinder: Service and Repair Disassembly and Reassembly DISASSEMBLY 1. Remove reservoir. a. Remove the set screw and pull out the reservoir. Torque: w/o ABS: 1.5 Nm (13 inch lbs.) w/ ABS: 1.7 Nm (16 inch lbs.) b. Remove the cap and strainer from the reservoir. 2. Remove 2 grommets. 3. Place cylinder in vise. Diagram Information and Instructions Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 276 Ground Points 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. How to Read Power Source Page 1844 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2405 Oxygen Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 4074 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2220 Ground Points 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. How to Read Power Source Page 654 CHART 24 Page 2611 CHART 18 CHART 19 Page 506 Page 4331 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 4660 Ground Points 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. How to Read Power Source Page 38 Cruise Control Module: Testing and Inspection Denso Made System ECU Power Source Circuit (Inspection 1) ECU Power Source Circuit (1) 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 Step 1 Page 966 Transmission Speed Sensor: Description and Operation 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. The No.2 vehicle speed sensor detects the rotation speed of the transmission output shaft and sends signals to the ECM. The ECM determines the vehicle speed based on these signals. An AC voltage is generated in the No.2 vehicle speed sensor coil as the rotor mounted on the output shaft rotates, and this voltage is sent to the ECM. The gear shift point and lock-up timing are controlled by the ECM based on the signals from this vehicle speed sensor and the throttle position sensor signal. If the No.2 vehicle speed sensor malfunctions, the ECM uses input signals from the No.1 vehicle speed sensor as a back-up signal. Page 3211 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3762 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 1721 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3356 Locations-J/B No.3 Behind The Instrument Panel Left (Fig 22) Page 869 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Testing and Inspection Canister Purge Solenoid: Testing and Inspection INSPECTION 1. REMOVE VSV (a) Disconnect the connector and 2 EVAP hoses from the VSV. (b) Remove the screw and VSV. 2. INSPECT VSV FOR OPEN CIRCUIT Using an ohmmeter, check that there is continuity between the terminals. Resistance: 30 - 34 ohms at 20°C (68°F) If there is no continuity, replace the VSV. 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. 4. INSPECT VSV OPERATION (a) Check that air does not flow from ports E to F. Page 1833 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Pressure Specification Fuel Pressure: Specifications Fuel System Pressure Fuel System Pressure Idle Pressure - No Vacuum 38 to 44 PSI psi Idle Pressure - With Vacuum 33-38 PSI 5 Minutes After Ignition Off 21 PSI or More Page 1874 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2459 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 1691 Ground Points 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. How to Read Power Source Specifications Case: Specifications Service Specifications Transmission Case Bushing, Maximum ........................................................................................................................................... 38.19 mm (1.5035 inch) Tightening Specifications Overdrive Support X Transmission Case ............................................................................................................................... 25 Nm (260 kg-cm, 19 ft. lbs.) Oil Pump X Transmission Case ............................................................................................................................................. 22 Nm (220 kg-cm, 16 ft. lbs.) Valve Body X Transmission Case ........................................................................................................................................... 10 Nm (100 kg-cm, 7 ft. lbs.) Oil Pan X Transmission Case .............................................................................................................................................. 7.4 Nm (75 kg-cm, 65 inch lbs.) Extension Housing X Transmission Case .............................................................................................................................. 36 Nm (370 kg-cm, 27 ft. lbs.) Transmission Housing: 10 mm Bolt .......................................................................................................................................... .............................. 34 Nm (345 kg-cm, 25 ft. lbs.) 12 mm Bolt ........................................................... ............................................................................................................. 57 Nm (580 kg-cm, 42 ft. lbs.) Union ................................................................................................................................................... .................................. 29 Nm (300 kg-cm, 22 ft. lbs.) Parking Lock Pawl Bracket ................................................................................................................................................. 7.4 Nm (75 kg-cm, 65 inch lbs.) Diagram Information and Instructions Camshaft Position Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3331 Overdrive Indicator Lamp: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1862 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 1452 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 947 Ground Points 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. How to Read Power Source Page 4307 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3251 Key to Diagrams Power Window Page 3141 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Diagram Information and Instructions Air Flow Meter/Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 4870 Auxiliary Power Outlet: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 2742 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1340 17. REMOVE NO.1 TIMING CHAIN TENSIONER SLIPPER AND NO.1 VIBRATION DAMPER a. Remove the bolt and slipper. b. 2RZ-FE: Remove the 2 bolts and No.1 damper. c. 3RZ-FE: Remove the bolt, nut and No.1 damper. 18. 2RZ-FE: REMOVE CRANKSHAFT POSITION SENSOR ROTOR 19. 2RZ-FE: REMOVE TIMING CHAIN OIL JET Remove the bolt, oil jet and gasket. 20. REMOVE NO.2, NO.3 VIBRATION DAMPERS AND NO.2 CHAIN TENSIONER a. Install a pin to the No.2 chain tensioner and lock the plunger. b. Remove the bolt and No.2 damper. c. Remove the 2 bolts and No.3 damper. d. Remove the nut and No.2 chain tensioner. Page 4671 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Cooling System - Radiator Cap Inspection Procedure Radiator Cap: Technical Service Bulletins Cooling System - Radiator Cap Inspection Procedure ENGINE EG014-05 Title: RADIATOR CAP INSPECTION Models: All Toyota Models March 28, 2005 Introduction The procedure for inspecting the radiator cap has been revised. Please refer to the following procedures when inspecting the radiator cap on all Toyota models. Applicable Vehicles ^ All Toyota and Scion models. Required Equipment Warranty Information Diagram Information and Instructions Intake Air Temperature Sensor: Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 2214 Step 2 TOYOTA hand-held tester Step 1 Step 2 OBD-II scan tool (excluding TOYOTA hand-held tester) Page 4739 Battery: Specifications Information not supplied by the manufacturer. Page 1797 CHART 14 Page 1308 Intake Manifold: Service and Repair For information regarding the service and repair of this component and the system that it is a part of, please refer to Cylinder Head Assembly; Service and Repair; Removal and Installation. With Locking Differential Drain Plug: Specifications With Locking Differential Drain Plug ............................................................................................................................................ ..................................................... 49 Nm (36 ft. lbs.) Page 2073 Spark Plug: Application and ID Recommended Spark Plugs ND K16R-U NGK BKR5EYA Page 1955 Key to Diagrams Power Window Page 253 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 129 Step 6 Step 7 INSPECTION PROCEDURE Locations Transmission Speed Sensor: Locations Vehicle Speed Sensor Location Page 1889 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 1489 REMOVAL 1. DRAIN ENGINE COOLANT 2. REMOVE RADIATOR GRILLE a. Remove the 4 screws, 2 clips and clearance lights. b. Remove the 2 filler. c. Remove the 11 clips and radiator grille. Page 3254 Crankshaft Position Sensor: Diagnostic Aids Disconnection of Male and Female Connectors 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. How to Replace Terminals Special Tool With terminal retainer or secondary locking device 1. Prepare The Special Tool 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 Secondary Locking Device Or Terminal Retainer 3. Disengage The Secondary Locking Device Or Terminal Retainer. Page 1451 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 590 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 123 Chart 2 Of 2 Page 347 Brake Switch (Cruise Control): Testing and Inspection Ford Made System Stop Light Switch Circuit CIRCUIT DESCRIPTION When the brake is on, battery positive voltage normally applies through the STOP fuse and stop light switch to terminal STP- of the ECU and the ECU turns the cruise control off. A fail-safe function is provided so that cancel functions normally, even if there is a malfunction in the stop light signal circuit. If the harness connected to terminal STP- has an open circuit1 terminal STP- will have battery positive voltage and the cruise control will be turned off. Also, when the brake is on, the magnetic clutch is cut mechanically by the stop light switch, turning the cruise control off. WIRING DIAGRAM Step 1 Page 2556 Page 499 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 864 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 308 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: 1 Indicates Relay Block No. 1. Connector C: Indicates the connector to be connected to a part (the numeral indicates the pin No.) Explanation of pin use. The pins shown are only for the highest grade, or only include those in the specification. D: Connector Color Connectors not indicated are milky white in color. E: ( ) is used to indicate different wiring and connector, etc. when the vehicle model, engine type, or specification is different. F: Indicates related system. Wiring Harness Connector G: Indicates the wiring harness and wiring harness connector. The wiring harness with male terminal is shown with arrows. Outside numerals are pin numbers. 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. H: Represents a part (all parts are shown in sky blue). The code is the same as the code used in parts position. Junction Block I: 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 (different junction blocks are shaded differently for further clarification). Wiring Color J: Indicates the wiring color. Wire colors are indicated by an alphabetical code. B = Black BR = Brown G = Green GR = Gray L = Blue LG = Light Green 0 = Orange P = Pink Page 4737 The charger starts charging upon completion of testing. The screen displays the status of charge. 13. Read or print the battery test results. P 1/4: BATTERY RESULTS P 2/4: STATE OF CHARGE (SOC) P 3/4: STATE OF HEALTH (SOH) P 4/4: WARRANTY CODE To print: Align the Midtronics IR Printer (P/N 00002-A0870, component of P/N 00002-V8150-KIT) in front of the IR port on the charger and select the PRINT soft key. Battery Charging Results Once the test completes, proceed with 1 of the 3 procedures below according to the BATTERY CONDITION results. 1. Battery Condition: "GOOD BATTERY" Return the battery to service. 2. Battery Condition: "REPLACE BATTERY" Replace the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. NOTE: A REPLACE BATTERY result may also mean a poor connection between the battery cables and the battery. Retest the battery using the out-of-vehicle test before replacing it. 3. Battery Condition: "BAD CELL-REPLACE" Replace the battery. The decision indicates a bad cell within the battery. Print the RESULTS screen for WARRANTY CODE by pressing the PRINT soft key. Page 2234 Crankshaft Position Sensor: Testing and Inspection INSPECTION NOTICE: "Cold" and "Hot" in these sentences express the temperature of the sensors 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). INSPECT CRANKSHAFT POSITION SENSOR RESISTANCE Using an ohmmeter, measure the resistance between terminals. Resistance (NE+ and NE-): Cold: 1,630 - 2,740 ohms Hot: 2,065 - 3,225 ohms If the resistance is not as specified, replace the crankshaft position sensor. Page 25 Finding A Short Circuit 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: 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) Voltage Check Page 831 Page 3379 Shift Indicator: Testing and Inspection CIRCUIT DESCRIPTION The propeller shaft and wheels are free even when the transmission shift lever is set to P as long as the transfer shift lever is in Neutral position. The A/T.P. indicator light lights up to warn the drive that the propeller shaft and wheels are not locked. If the A/T.P. indicator light goes on, the transfer shift lever should be shifted out of N position. WIRING DIAGRAM Step 1 Page 2106 Page 306 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 84 Engine Compartment (Fig 18) Instrument Panel (Fig 18) Locations Page 926 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1523 Page 2643 Finding A Short Circuit 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: 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) Voltage Check Removal and Installation Brake Caliper: Service and Repair Removal and Installation REMOVAL 1. Remove front wheel. 2. Disconnect flexible hose. Remove the union bolt and 2 gaskets from the caliper, then disconnect the flexible hose from the caliper. Torque: 30 Nm (22 ft. lbs.) HINT: At the time of installation, install the flexible hose lock securely in the lock hole in the caliper. 3. Remove caliper. Remove the 2 mounting bolts and caliper. Torque: 123 Nm (90 ft. lbs.) Page 583 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3489 Key to Diagrams Power Window Page 1081 Coolant: Service Precautions 1. Toyota Long Life Antifreeze Coolant is recommended by the manufacturer for maximum protection. 2. Mixing green and red colored coolants is not recommended. Page 1916 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. NOTE: Do not remove the terminal retainer from connector body. Non-Waterproof Type Connector A - 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. "Case 1" Raise the terminal retainer up to the temporary lock position. Non-Waterproof Type Connector "Case 2" Open the secondary locking device. Non-Waterproof Type Connector Page 287 Voltage Check a. Establish conditions in which voltage is present at the check point. Example: A- Ignition SW ON B- Ignition SW and SW 1ON 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 a light instead of a voltmeter. Page 2915 Fuel Injector: Pressure, Vacuum and Temperature Specifications Pressure Drop Pressure Drop Resistance 12-16 ohms at 68 deg F Volume 69-88 cm3 (34.2-5.4 cu in.) Per 15 seconds Difference Between Injectors 5 cm3 (0.3 cu in.) or less Leakage 1 drop or less per 3 Minutes Page 2598 Page 4863 Location Of Connector Joining Wire Harness And Wire Harness, Ground Points (Fig 38) Junction Block and Wire Harness Connector Junction Block and Wire Harness Connector Page 2697 Power Source (Current Flow Chart) Power Source The "Current Flow Chart" images, 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. Current Flow Chart The chart shows the route by which current flows from the battery to each electrical source (Fusible Link, circuit Breaker, Fuse, etc.) and other parts. Page 2599 O2S Application Table O2S Failure Threshold Charts Page 646 CHART 18 CHART 19 Page 3795 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 1612 Fuel Pump Relay: Testing and Inspection INSPECTION 1. REMOVE LOWER FINISH NO.1 PANEL 2. REMOVE CIRCUIT OPENING RELAY 3. INSPECT CIRCUIT OPENING RELAY CONTINUITY (a) Using and ohmmeter, check that there is continuity between terminals STA and E1. If there is no continuity, replace the relay. (b) Check that there is continuity between terminals +B and FC. If there is no continuity, replace the relay. (c) Check that there is no continuity between terminals +B and FP. If there is continuity, replace the relay. 4. INSPECT CIRCUIT OPENING RELAY OPERATION (a) Apply battery positive voltage across terminals STA and E1. (b) Using an ohmmeter, check that there is continuity between terminals +B and FP. (c) Apply battery positive voltage across terminals +B and FC. (d) Check that there is continuity between terminals +B and FP. If operation is not as specified, replace the relay. 5. REINSTALL CIRCUIT OPENING RELAY 6. REINSTALL LOWER FINISH NO.1 PANEL Page 1673 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ]. Page 3631 Step 1 Step 2 Page 3786 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 3283 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Diagrams Specifications Differential Axle Housing: Specifications Axle Housing To: Backing Plate ....................................................................................................................................... ................................................. 68 Nm (50 ft. lbs.) Page 1663 Air Flow Meter/Sensor: Service and Repair REMOVAL 1. REMOVE AIR CLEANER CAP WITH MAF METER (a) Disconnect the MAF meter connector and wire clamp. (b) Loosen the air cleaner hose clamp. (c) Disconnect the air hose from air cleaner cap. (d) Loosen the 4 clips and remove the air cleaner cap together with the MAF meter. 2. REMOVE MAF METER FROM AIR CLEANER CAP Remove the 4 nuts, MAF meter and gasket. INSTALLATION 1. INSTALL MAF METER TO AIR CLEANER CAP (a) Place a new gasket on the air cleaner cap. (b) install the MAF meter with the 4 nuts. Torque: 8.5 N.m (85 kgf.cm1 74 in.lbf) 2. INSTALL MAF METER WITH AIR CLEANER CAP A/C Drive Belt: Testing and Inspection A/C 1. INSPECT DRIVE BELT'S INSTALLATION CONDITION Check that the drive belt fits properly in the ribbed grooves. 2. INSPECT DRIVE BELT TENSION Using a belt tension gauge, check the drive belt tension. Drive belt tension: New belt : 160 ± 25 lb Used belt : 100 ± 20 lb 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 the drive belt, check that it fits properly in the ribbed grooves. Page 335 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. ABS/TCS - Zero Point Calibration Information Steering Angle Sensor: Technical Service Bulletins ABS/TCS - Zero Point Calibration Information T-SB-0020-08 March 25, 2008 Disconnect Battery & Perform Zero Point Calibration After Wheel Alignment Adjustment Service Category Brake Section Brake Control/Dynamic Control System Market USA Applicability Introduction The purpose of this TSB is to provide information on when and how to perform the zero point calibration on vehicles equipped with Vehicle Stability Control (VSC). Momentarily disconnecting the battery is a necessary step for performing the zero point calibration. Warranty Information Required Tools & Equipment ^ Additional TIS techstream units may be ordered by calling Approved Dealer Equipment (ADE). ^ The Toyota Diagnostic Tester and CAN Interface Module may also be used to perform the service procedures listed in this bulletin. Preliminary Information Perform this procedure if any of these repairs have been performed on the vehicle: ^ Wheel alignment has been adjusted. ^ Any chassis components have been removed/installed or replaced. Page 2522 Glossary Of Terms And Symbols (Part 2 Of 2) How To Read Ground Points Page 2530 Waterproof Type Connector B - For Waterproof Type Connector HINT: Terminal retainer color is different according to connector body. Example: Terminal Retainer : Connector Body Black or White : Gray Black or White : Dark Gray Gray or White : Black Waterproof Type Connector "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. Page 2054 Fuel Pressure Release: Service and Repair GENERAL PRECAUTIONS 1. Before working on the fuel system, disconnect the negative (-) terminal cable from the battery. HINT: Any diagnostic trouble code retained by the ECM will be erased when the battery negative (-) terminal removed from The battery. Therefore, if necessary, read the diagnostic trouble code(s) 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. FUEL PRESSURE RELEASE PROCEDURE WHEN DISCONNECTING THE HIGH PRESSURE FUEL LINE, A LARGE AMOUNT OF GASOLINE WILL SPILL OUT, SO OBSERVE THESE PROCEDURES: - Put a container under the connection. - Slowly loosen the connection. - Disconnect the connection. - Plug the connection with a rubber plug. WHEN CONNECTING THE FLARE NUT OR UNION BOLT ON THE HIGH PRESSURE PIPE UNION, OBSERVE THESE PROCEDURES: Union Bolt Type: - Always use a new gasket. - Tighten the union bolt by hand. - Tighten the union bolt to the specified torque. Torque: 29 N.m (300 kgf.cm, 22 ft.lbf) Flare Nut Type: Apply a light coat of engine oil to the flare and tighten the flare nut by hand. - Using SST, tighten the flare nut to the specified torque. SST 09631-22020 HINT: Use a torque wrench with a fulcrum length of 30 cm (11.81 in.). Diagram Information and Instructions Coolant Temperature Sensor/Switch (For Computer): Diagram Information and Instructions Glossary Of Terms And Symbols (Part 1 Of 2) Page 3120 Waterproof Type Connector "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 Push the terminal retainer down to the temporary lock position. Locking Lug C. Release the locking lug from terminal and pull the terminal out from rear. Installation Of Terminal To Connector 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. Page 2272 Secondary Locking Device b Push the secondary locking device or terminal retainer into the full lock position. 5. Connect Connector Continuity and Resistance Check 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. Continuity And Resistance Check 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. Continuity And Resistance Check c. Use a volt/ohmmeter with high impedance (10 K Ohms/Volt minimum) for troubleshooting of the electrical circuit. Finding A Short Circuit Page 3090 R = Red V = Violet W = White Y = Yellow The first letter indicates the basic wire color and the second letter indicates the color of the stripe. Splice Point K: Indicates a wiring Splice Point (Codes are "E", for the Engine Room, "I" for the Instrument Panel, and "B" for the Body). The Location of Splice Point I 5 is indicated by the shaded section. L: Page No. M: Indicates a shielded cable. N: Indicates a ground point. The first letter of the code for each ground point(s) indicates the components location, e.g, E for the Engine Compartment, "I" for the Instrument Panel and Surrounding area, and "B" for the Body and Surrounding area. Pin Number Of The Connector O: Indicates the pin number of the connector. The numbering system is different for female and male connectors. Example: Numbered in order Numbered in order from upper left to from upper right to lower right lower left P: When 2 parts both use one connector in common, the parts connector name used in the wire routing section is shown in square brackets [ ].